WO2017026346A1 - Method for manufacturing layered film, and device for manufacturing layered film - Google Patents

Method for manufacturing layered film, and device for manufacturing layered film Download PDF

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Publication number
WO2017026346A1
WO2017026346A1 PCT/JP2016/072783 JP2016072783W WO2017026346A1 WO 2017026346 A1 WO2017026346 A1 WO 2017026346A1 JP 2016072783 W JP2016072783 W JP 2016072783W WO 2017026346 A1 WO2017026346 A1 WO 2017026346A1
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WIPO (PCT)
Prior art keywords
film
coating
thickness
laminated
coating film
Prior art date
Application number
PCT/JP2016/072783
Other languages
French (fr)
Japanese (ja)
Inventor
志由仁 河野
内海　京久
Original Assignee
富士フイルム株式会社
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Publication date
Application filed by 富士フイルム株式会社 filed Critical 富士フイルム株式会社
Priority to JP2017534385A priority Critical patent/JP6539348B2/en
Priority to CN201680046380.XA priority patent/CN107921700B/en
Publication of WO2017026346A1 publication Critical patent/WO2017026346A1/en
Priority to US15/892,637 priority patent/US20180162113A1/en

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    • B32B37/15—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state
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    • B32B2250/00—Layers arrangement
    • B32B2250/24—All layers being polymeric
    • B32B2250/242—All polymers belonging to those covered by group B32B27/32
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/24—All layers being polymeric
    • B32B2250/244—All polymers belonging to those covered by group B32B27/36
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/24—All layers being polymeric
    • B32B2250/246—All polymers belonging to those covered by groups B32B27/32 and B32B27/30
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/40—Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/10—Coating on the layer surface on synthetic resin layer or on natural or synthetic rubber layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/26—Polymeric coating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/536—Hardness
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/54—Yield strength; Tensile strength
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/584—Scratch resistance
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/724—Permeability to gases, adsorption
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/724—Permeability to gases, adsorption
    • B32B2307/7242—Non-permeable
    • B32B2307/7244—Oxygen barrier
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/732—Dimensional properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
    • B32B2309/08—Dimensions, e.g. volume
    • B32B2309/10—Dimensions, e.g. volume linear, e.g. length, distance, width
    • B32B2309/105—Thickness

Definitions

  • the present invention relates to the production of a laminated film in which a cured layer is sandwiched between films.
  • Various devices such as gas barrier films, protective films, optical filters, antireflection films, and quantum dot films are used in various devices such as optical devices, display devices such as liquid crystal displays and organic EL displays, semiconductor devices, and thin film solar cells. Has been.
  • a laminated film constituted by laminating a plurality of films and layers that express a target function is known.
  • a quantum dot film has a configuration in which a quantum dot layer obtained by dispersing and curing quantum dots in a resin is sandwiched between two films as an example.
  • a gas barrier film or the like is used as a film for sandwiching the quantum dot layer in order to prevent deterioration of the quantum dot due to oxygen or the like.
  • a cured layer is formed by applying and curing an electron beam curable resin composition on a molding substrate, and, on the other hand, a coating made of an electron beam curable resin composition on a sheet substrate.
  • a film (coating layer) is formed, and the cured layer and the coating film are faced to laminate a molding substrate and a sheet-like substrate, and this coating is cured by irradiating an electron beam or the like to the cured layer.
  • a method for producing a laminated film is described, in which a laminated film formed by laminating a cured layer, a cured layer and a sheet-like substrate is peeled off from the molding substrate.
  • the molding support include a cylindrical drum and a molding film.
  • Patent Document 2 discloses an application step of applying an ultraviolet curable resin to the surface of the first sheet fed from the supply unit, and a first curing step of partially curing the ultraviolet curable resin by the first ultraviolet curing unit. And a pressure bonding step including a cotter for controlling the thickness, a second pressure sheet that is bonded to the first sheet by the second sheet fed from the supply means to form a long laminate, and a second ultraviolet ray A laminated film including a second curing step of further curing the ultraviolet curable resin by the curing means, and making the ultraviolet irradiation amount by the second ultraviolet curing means larger than the ultraviolet irradiation amount by the first ultraviolet curing means The manufacturing method is described.
  • An object of the present invention is to solve such problems of the prior art, and in the production of a laminated film in which a cured layer is sandwiched between films, the thickness unevenness of the cured layer is greatly suppressed and cured. It is providing the manufacturing method and manufacturing apparatus of a laminated film which can manufacture the laminated film with the high uniformity of the thickness of a layer.
  • the method for producing a laminated film of the present invention applies a coating solution containing an actinic radiation curable resin to the surface of the first film while continuously conveying the first film, A coating film forming step for forming a coating film; A laminating step of laminating the second film on the coating film while continuously conveying the second film; A curing step of forming a cured layer by irradiating actinic radiation, curing the coating film while continuously transporting the coating film sandwiched between the first film and the second film, and Provided is a method for producing a laminated film, wherein the coating film forming step, the laminating step, and the curing step are all performed in a state where the first film is wound around a backup roller.
  • the second film is wound around a laminating roller separated from the first film and laminated on the coating film.
  • the distance of a bonding roller and a backup roller is more than the sum total of the thickness of a 1st film, the thickness of a coating film, and the thickness of a 2nd film.
  • the distance of a bonding roller and a backup roller is less than the sum total of the thickness of a 1st film, the thickness of a coating film, and the thickness of a 2nd film.
  • the film thickness of a coating film with the 2nd film wound around a bonding roller by adjusting the clearance gap between a backup roller and a bonding roller.
  • the tension applied to the second film is preferably 100 N / m or less.
  • the active line which hardens a coating film in a hardening process is an electromagnetic wave whose half value width of intensity distribution with respect to a wavelength is 100 nm or less.
  • the surface temperature of the backup roller is preferably adjusted to 15 to 55 ° C.
  • the tension applied to the first film is T1
  • the Young's modulus in the transport direction of the first film is E1
  • the thickness of the first film is d1
  • the tension applied to the second film is T2
  • the second film The following formula 0.05 ⁇ [T2 / (E2 ⁇ d2)] / [T1 / (E1 ⁇ d1)] ⁇ 20 where the Young's modulus in the transport direction is E2 and the thickness of the second film is d2. It is preferable to satisfy.
  • the laminated film manufacturing apparatus of the present invention includes a backup roller, A conveying means for continuously conveying the first film around the backup roller; A coating film forming means for applying a coating liquid containing an actinic radiation curable resin to the first film wound around the backup roller, which is arranged facing the backup roller, and forming a coating film; Laminating means for laminating the second film on the coating film while continuously conveying the second film, on the downstream side in the conveying direction of the first film of the coating film forming means, Curing means for irradiating the laminated body sandwiching the coating film between the first film and the second film, which is disposed facing the backup roller, on the downstream side in the conveying direction of the first film of the laminating means;
  • the manufacturing apparatus of the laminated film characterized by having these is provided.
  • the thickness unevenness of the cured layer is greatly suppressed, and a laminated film with high uniformity of the thickness of the cured layer is obtained. Can be manufactured.
  • FIG. 1 is a diagram conceptually illustrating an example of a laminated film manufacturing apparatus of the present invention.
  • FIG. 2 is a partially enlarged view of FIG.
  • FIG. 3 is a diagram conceptually illustrating another example of the laminated film manufacturing apparatus of the present invention.
  • FIG. 4 is a partially enlarged view of FIG.
  • a numerical range expressed using “to” means a range including numerical values described before and after “to” as a lower limit value and an upper limit value.
  • FIG. 1 an example of the manufacturing apparatus of the laminated film of this invention which enforces the manufacturing method of the laminated film of this invention is shown notionally.
  • FIG. 2 shows a partially enlarged view of FIG.
  • a laminated film production apparatus 10 shown in FIG. 1 produces a laminated film 20 in which a cured layer 16 is sandwiched between a first film 12 and a second film 14.
  • laminated film manufacturing apparatus 10 is referred to as “manufacturing apparatus 10”, “first film 12” as “first film 12”, and “second film 14” as “second film 14”.
  • the manufacturing apparatus 10 in the illustrated example basically includes a first supply unit 24 that supplies the first film 12, a second supply unit 26 that supplies the second film 14, a backup roller 28, a coating device 30, A laminating roller 32, a curing device 34, and a peeling roller 36 are included.
  • the manufacturing apparatus 10 sends out a film from a roll formed by winding a long film (sheet-like material), performs film formation while conveying the film in the longitudinal direction, and winds the processed film into a roll. It is a so-called roll-to-roll manufacturing device that rotates. Specifically, the manufacturing apparatus 10 sends out the first film 12 from the first supply unit 24, winds it around the backup roller 28, and transports the first film 12 in the longitudinal direction. A coating liquid 40 is formed by applying a coating liquid (paint / coating composition) to the surface of the film 12. Next, the second film 14 is sent out from the second supply unit 26, and the second film 14 is laminated on the surface of the coating film 40. Next, the actinic ray A is irradiated by the curing device 34 to cure the coating film 40 sandwiched between the first film 12 and the second film 14 to form the cured layer 16, thereby manufacturing the laminated film 20.
  • a coating liquid is formed by applying a coating liquid (paint / coating composition) to the surface of the film
  • the manufacturing method and the manufacturing apparatus of the laminated film of the present invention include a coating film forming process for forming the coating film 40 on the surface of the first film 12, a laminating process for laminating the second film 14 on the coating film 40, And all the hardening processes which harden the coating film 40 pinched
  • the first supply unit 24 is a part that supplies the first film 12 to the backup roller 28.
  • the 1st supply part 24 has the rotating shaft 24a.
  • the rotating shaft 24a is loaded with a first film roll 12R formed by winding the long first film 12 into a roll shape.
  • the 1st film 12 is sent out from the 1st film roll 12R by rotating the rotating shaft 24a.
  • the first film 12 sent out from the first supply unit 24 is wound around the backup roller 28 and conveyed along a predetermined path.
  • the transport of the laminated film 20 may be performed by a known method.
  • first film 12 and the second film 14 various types of films (sheet-like materials) used in known laminated films can be used.
  • films polyethylene (PE), polyethylene naphthalate (PEN), polyamide (PA), polyethylene terephthalate (PET), polyvinyl chloride (PVC), polyvinyl alcohol (PVA), polyacrylonitrile (PAN), polyimide (PI) , Transparent polyimide, polymethyl methacrylate resin (PMMA), polycarbonate (PC), polyacrylate, polymethacrylate, polypropylene (PP), polystyrene (PS), acrylonitrile-butadiene-styrene copolymer (ABS), cyclic olefin copolymer
  • the resin film include resin materials such as (COC), cycloolefin polymer (COP), and triacetyl cellulose (TAC).
  • At least one of the first film 12 and the second film 14 is preferably a gas barrier film.
  • a gas barrier film a film obtained by forming a gas barrier layer exhibiting gas barrier properties on the surface of a support is exemplified.
  • a gas barrier film formed by forming one or more combinations of an inorganic layer exhibiting gas barrier properties and an organic layer serving as a base layer of the inorganic layer is suitably used.
  • Preferred examples of the gas barrier layer and the inorganic layer exhibiting gas barrier properties include a layer made of silicon nitride, silicon oxynitride, silicon oxide, aluminum oxide, or the like.
  • bifunctional such as dipropylene glycol di (meth) acrylate (DPGDA), trimethylolpropane tri (meth) acrylate (TMPTA), dipentaerythritol hexa (meth) acrylate (DPHA), etc.
  • DPGDA dipropylene glycol di (meth) acrylate
  • TMPTA trimethylolpropane tri (meth) acrylate
  • DPHA dipentaerythritol hexa
  • the acrylic resin and methacrylic resin which have as a main component the monomer and oligomer polymer of a trifunctional or more than trifunctional acrylate and / or methacrylate are illustrated suitably.
  • the first film 12 and the second film 14 have an oxygen permeability of 1 ⁇ 10 ⁇ 4 to 1 cm 3 / (m 2 ⁇ day ⁇ atm).
  • the oxygen transmission rate may be measured using an oxygen gas transmission rate measuring device (manufactured by MOCON, OX-TRAN 2/20) under the conditions of a temperature of 23 ° C. and a relative humidity of 90%.
  • At least one of the first film 12 and the second film 14 preferably has a hard coat layer.
  • the hard coat layer means a layer having scratch resistance
  • a layer having a scratch hardness (pencil method) (conforming to JIS K-5600 (1999) standard) (JIS: Japanese Industrial Standards) is H or more.
  • the scratch hardness is more preferably 2H or more, and particularly preferably 3H or more.
  • the hard coat layer is a composition containing a compound having an unsaturated double bond, a polymerization initiator, and, if necessary, translucent particles, a fluorine-containing or silicone compound, and an organic solvent (hard coat layer forming material). Can be formed by coating, drying and curing.
  • a compound having an unsaturated double bond a polymerization initiator, and, if necessary, translucent particles, a fluorine-containing or silicone compound, and an organic solvent (hard coat layer forming material).
  • An organic solvent hard coat layer forming material
  • At least one of the first film 12 and the second film 14 preferably has a light diffusion layer.
  • the light diffusion layer means a layer that scatters light passing therethrough.
  • the light diffusing layer can be formed by coating, drying, and curing a coating liquid containing translucent particles, matrix-forming components (such as binder monomers) and an organic solvent.
  • paragraphs [0025] to [0089] of JP-A-2009-258716 can be referred to, but the present invention is not limited thereto.
  • the thickness of the first film 12 and the second film 14 is preferably 10 to 100 ⁇ m, and preferably 15 to 60 ⁇ m, from the viewpoint of reducing the thickness of the laminated film 20 and preventing wrinkles. More preferred. Note that the thicknesses of the first film 12 and the second film 14 may be the same or different. What is necessary is just to set the thickness of the 1st film 12 and the 2nd film 14 suitably according to the use etc. of the laminated
  • the first film 12 and the second film 14 may be the same or different. That is, as an example, the first film 12 and the second film 14 may be the same gas barrier film, the same resin film, different gas barrier films, or different resin films. It may be a gas barrier film and a resin film. However, in any case, in the present invention, at least the second film 14 needs to sufficiently transmit the actinic radiation A irradiated by the curing device 34.
  • the first film 12 sent out from the first supply unit 24 is wound around the backup roller 28.
  • the backup roller 28 is a cylindrical member made of metal, for example, and rotates with the first film 12 wound around the side surface of the cylinder. Wrapping around the backup roller 28 means a state in which the first film 12 is in contact with the surface of the backup roller 28 at a certain wrap angle. Therefore, during the continuous conveyance, the first film 12, or the coating film 40, or the second film 14 moves in synchronization with the rotation of the backup roller 28. As described above, in the present invention, the formation of the coating film 40 on the first film 12, the lamination of the second film 14 on the coating film 40, and the curing of the coating film 40 are all performed by using the backup roller for the first film 12. 28.
  • the first film 12 is wound around the backup roller 28 from at least a position upstream from the position where the coating film 40 is formed on the first film 12 to a position downstream from the irradiation position of the active ray A. Become.
  • upstream and downstream are both upstream and downstream in the transport direction of the first film 12.
  • the backup roller 28 incorporates a temperature adjusting means for adjusting the surface temperature of the backup roller 28 as a preferred mode.
  • a temperature adjusting means various known methods such as circulation of a temperature adjusting medium, a method using a heater or a cooling means can be used.
  • the surface temperature of the backup roller 28 is preferably adjusted to 15 to 55 ° C, more preferably 20 to 40 ° C.
  • the second film is laminated on the coating film 40, and then the active ray A is irradiated to cure the coating film 40 to form the cured layer 16.
  • the first film 12 and the second film 14 may be heated and deformed. If the first film 12 or the second film 14 is deformed when the coating film 40 is cured, the thickness of the cured layer 16 varies due to the deformation, and thickness unevenness occurs in the cured layer 16.
  • the temperature of the backup roller 28 By adjusting the temperature of the backup roller 28 to 55 ° C.
  • the deformation of the first film 12 and the second film 14 due to heating can be suitably prevented, and unevenness in the thickness of the cured layer 16 can be prevented.
  • the diameter of the backup roller 28 may be set as appropriate according to the size of the manufacturing apparatus 10 and the like. According to studies by the present inventors, the diameter of the backup roller is preferably 100 to 1000 mm, more preferably 200 to 500 mm, taking into account curled deformation of the laminated film, equipment cost, rotational accuracy, and the like.
  • the manufacturing apparatus 10 first transports the first film 12 around the backup roller 28 in the longitudinal direction while first transporting the surface of the first film 12 by the coating device 30 positioned facing the backup roller 28.
  • the coating liquid formation process which forms the coating film 40 by apply
  • various known liquid coating devices can be used as long as they can form the coating film 40 having a target film thickness in accordance with the coating solution to be coated. Examples include coating devices that apply coating solutions by die coating, curtain coating, rod coating, air knife coating, curtain coating, roller coating, wire bar coating, gravure coating, slide coating, etc. Is done.
  • the film thickness of the cured layer 16 may be appropriately set according to the use of the laminated film 20, the material for forming the cured layer 16, the action of the cured layer 16, the performance required for the cured layer 16, and the like. . According to the study of the present inventor, the film thickness of the coating film 40 is preferably 10 to 80 ⁇ m.
  • the coating liquid that becomes the coating film 40, that is, the cured layer 16 contains an actinic radiation curable resin.
  • the actinic radiation curable resin refers to a resin that is cured through a crosslinking reaction and a polymerization reaction when irradiated with actinic radiation.
  • Actinic rays refer to electromagnetic waves such as ultraviolet rays, electron beams, and radiation ( ⁇ rays, ⁇ rays, ⁇ rays, etc.).
  • the actinic radiation curable resin for example, a resin having a functional group of light (ultraviolet ray), electron beam, radiation curable polyfunctional monomer or polyfunctional oligomer is used, and among them, a photopolymerizable functional group is preferable.
  • the photopolymerizable functional group include unsaturated polymerizable functional groups such as a (meth) acryloyl group, a vinyl group, a styryl group, and an allyl group.
  • an organic solvent can be used as the solvent of the coating solution.
  • the organic solvent include alcohols, ketones, esters, aliphatic hydrocarbons, amides, ethers, and ether alcohols. These solvents are preferably used in combination of two or more, more preferably in combination of three or more.
  • the viscosity of a coating liquid is preferably 20 to 600 mPa ⁇ s, and more preferably 40 to 400 mPa ⁇ s, from the viewpoint of preventing mixing of bubbles and the uniformity of the thickness of the coating film 40. .
  • the coating solution contains substances that exhibit various functions such as quantum dots, organic electroluminescent materials, organic semiconductor materials, photoelectric conversion materials, thermoelectric conversion materials, dyes and pigments. May be. Among these, quantum dots are preferably used.
  • a quantum dot refers to a crystal particle having a nanoscale particle size and having optical characteristics due to a quantum confinement effect.
  • a quantum dot having a core-shell structure is known as a quantum dot.
  • the core-shell quantum dots include CdSe / ZnS, CdSe / CdS, CdTe / CdS, InP / ZnS, GaP / ZnS, Si / ZnS, and InN / GaN.
  • the quantum dot structure is not limited to the core-shell structure.
  • the quantum dot can change its optical characteristics by changing its size. The smaller the particle size of the quantum dots, the greater the energy emitted by the quantum dots.
  • the emission wavelength of the quantum dots can usually be adjusted by the composition and size of the particles.
  • quantum dots for example, paragraphs [0060] to [0066] of JP2012-169271A can be referred to, but the present invention is not limited thereto.
  • Quantum rods may be used. Quantum rods have the same characteristics as quantum dots and refer to elongated particles. As the quantum dots, commercially available products can be used without any limitation. Moreover, a quantum dot and a quantum rod can also be used simultaneously.
  • the laminated film in which the cured layer 16 includes at least one of quantum dots and quantum rods is also referred to as a quantum dot film.
  • a laminating roller 32 for laminating the second film 14 on the coating film 40 is disposed downstream of the coating device 30 so as to face the backup roller 28.
  • the laminate in which the coating film 40 is formed on the surface of the first film 12 is then conveyed to the laminating position P by the laminating roller 32 and supplied from the second supply unit 26 in the laminating process.
  • the second film 14 is wound around the laminating roller 32, guided to a predetermined conveyance path, and laminated on the coating film 40.
  • the 2nd supply part 26 has the rotating shaft 26a.
  • a second film roll 14R formed by winding the long second film 14 into a roll shape is loaded on the rotating shaft 26a.
  • the 2nd film 14 is sent out from the 2nd film roll 14R by rotating the rotating shaft 26a.
  • the second film 14 delivered from the second supply unit 26 is wound around the laminating roller 32, conveyed along a predetermined path, and laminated (laminated) on the coating film 40 at the laminating position P.
  • the distance L1 that is the shortest distance between the surface of the backup roller 28 and the surface of the bonding roller 32 is the thickness d1 of the first film 12 and the thickness of the coating film 40. It is more than the sum of dc and the thickness d2 of the second film.
  • the distance L1 is also referred to as “distance L1 between the backup roller 28 and the bonding roller 32”. That is, “L1 ⁇ d1 + dc + d2”.
  • the second film 14 is not in contact with the coating film 40 in a state where it is wound around the bonding roller 32, that is, the second film 14 is not wound around the bonding roller at the lamination position P.
  • the manufacturing apparatus 10 has such a configuration, so that the laminating roller 32 does not press the coating film 40, and the second film 14 also does not press the coating film 40.
  • the second film 14 can be laminated on the coating film 40. Therefore, even if the second film 14 is laminated on the coating film 40, it is possible to prevent the film thickness of the coating film 40 from fluctuating due to the lamination of the second film 14. Therefore, according to the manufacturing apparatus 10, if the coating apparatus 30 has a target film thickness and has a uniform film thickness and a highly accurate coating film 40, the target film thickness is obtained. A cured layer 16 having a uniform film thickness can be produced.
  • the 2nd film 14 In order to transport the second film 14 properly, it is necessary to apply a certain amount of tension to the second film 14.
  • the 2nd film 14 In the manufacturing apparatus 10, between the bonding roller 32 and the lamination position P, the 2nd film 14 is floating in the air in a state where nothing is supported. Therefore, in this floating region, a wave-like deformation occurs in the width direction of the second film 14 due to the tension applied to the second film 14.
  • the width direction is a direction orthogonal to the transport direction.
  • the second film 14 can be laminated on the coating film 40 without affecting the coating film 40, but such wavy deformation of the second film 14 causes film thickness unevenness in the coating film 40.
  • the tension applied to the second film 14 is preferably 100 N / m or less, and more preferably 50 N / m or less.
  • the second film 14 may press the coating film 40 and change the film thickness of the coating film 40.
  • the tension applied to the second film 14 can be prevented from affecting the film thickness of the coating film 40, and more of the cured layer 16. A laminated film with little thickness unevenness can be obtained.
  • the tension applied to the first film 12 is T1
  • the Young's modulus in the transport direction of the first film is E1
  • the thickness of the first film 12 is d1
  • the tension applied to the second film 14 is T2.
  • the Young's modulus in the transport direction of the second film 14 is E2
  • the thickness of the second film 14 is d2
  • the coating film 40 is cured to form the cured layer 16. Therefore, the laminated film 20 tends to be curled with the first film 12 inside. This curl can also be prevented by adjusting the tension applied to the first film 12 and the second film 14, but if the adjustment is not successful, the laminated film 20 is conversely changed to the second film 14. May curl with the inside. On the contrary, 0.05 ⁇ [T2 / (E2 ⁇ d2)] / [T1 / (E1 ⁇ d1)] ⁇ 20 By satisfying the above, it is possible to manufacture the laminated film 20 in which the curl with the first film 12 on the inside and the curl with the second film 14 on the inside are greatly reduced.
  • the rotation accuracy of the backup roller 28 and the bonding roller 32 is high, the radial runout is preferably 0.05 mm or less, and more preferably 0.01 mm or less.
  • a curing device 34 is disposed downstream of the bonding roller 32 so as to face the backup roller 28.
  • the laminate of the first film 12, the coating film 40, and the second film 14 obtained by laminating the second film 14 on the coating film 40 is conveyed to the curing device 34 that performs the curing process while being wound around the backup roller. .
  • the curing device 34 irradiates the coating film 40 sandwiched between the first film 12 and the second film 14 with the active ray A, thereby curing the coating film 40 to form the cured layer 16 and the laminated film 20.
  • the active rays A are electromagnetic waves such as ultraviolet rays, electron beams, and radiation ( ⁇ rays, ⁇ rays, ⁇ rays, etc.) as described above.
  • the curing device 34 various types of devices that use a known light source that irradiates the active ray A that can cure the coating film 40 can be used.
  • the curing device 34 uses a light source that emits ultraviolet rays.
  • Various known light sources can be used as the light source for irradiating ultraviolet rays.
  • LED Light Emitting Diode
  • laser light source low pressure mercury lamp, medium pressure mercury lamp, high pressure mercury lamp, super high pressure mercury lamp, carbon arc lamp, metal halide lamp, xenon lamp and the like are exemplified.
  • the active ray A is preferably an electromagnetic wave having an intensity distribution peak in a wavelength region where the coating film 40 can be cured, and an intensity distribution (peak) with respect to the wavelength having a half width of 100 nm or less.
  • An electromagnetic wave having a half width of 50 nm or less is more preferable. That is, the curing device 34 has an intensity distribution peak in a wavelength region where the coating film 40 can be cured, and can emit an active ray A having a half value width of the intensity distribution (peak) with respect to the wavelength of 100 nm or less. It is preferable to use a light source such as a laser light source.
  • the coating film 40 is cured by irradiating the coating film 40 sandwiched between the first film 12 and the second film 14 with the active ray A.
  • the actinic radiation A is also absorbed by the first film 12 and the second film 14, the first film 12 and the second film 14 are thereby heated and may be deformed. If the first film 12 or the second film 14 is deformed when the coating film 40 is cured, the thickness of the cured layer 16 varies due to the deformation, and thickness unevenness occurs in the cured layer 16.
  • the first film 12 and the second film 14 are prevented from being heated by an electromagnetic wave of an unnecessary component that does not contribute to the curing of the coating film 40. it can. As a result, it is possible to prevent unevenness in the thickness of the cured layer 16 due to the deformation of the first film 12 and the second film 14 due to heating.
  • the irradiation amount of the actinic radiation A irradiated by the curing device 34 is set appropriately according to the transport speed of the first film 12, the film thickness of the coating film 40, etc., the irradiation amount that can reliably cure the coating film 40 is set. Good.
  • the irradiation amount of the active wiring A curing device 34 is irradiated is preferably 100 ⁇ 10000mJ / cm 2, more preferably 1000 ⁇ 4000mJ / cm 2.
  • the irradiation amount of the actinic ray A is preferable in that the appropriate coating film 40 can be stably cured.
  • the distance L2 from the lamination position P to the irradiation position of the active ray A by the curing device 34 is appropriately determined according to the size of the backup roller 28, the film thickness of the coating film 40, the irradiation amount of the active ray A by the curing device 34, etc. You only have to set it.
  • the distance L2 from the lamination position P to the irradiation position of the active ray A by the curing device 34 is preferably 30 mm or more, and more preferably 50 mm or more. This is preferable in that the leveling effect of the coating film 40 after the second film 14 is laminated can be sufficiently obtained, and the film thickness distribution of the cured layer 16 can be improved.
  • the temperature of the first film 12 and the second film 14 before the coating film 40 is irradiated with the active ray A, and the first film 12 and the second film 14 after the coating film 40 is irradiated with the active ray A are used.
  • the difference from the temperature of the two films 14 is preferably 25 ° C. or less. By setting this temperature difference to 25 ° C. or less, wrinkles can be prevented from occurring in the first film 12 and the second film 14.
  • a peeling roller 36 is disposed downstream of the curing device 34.
  • the laminated film 20 produced by forming the cured layer 16 by curing the coating film 40 is then peeled off from the backup roller 28 by the peeling roller 36 and conveyed along a predetermined conveyance path to be wound around a winding shaft (not shown). And a roll in which the laminated film 20 is wound.
  • the production method and production of the laminated film of the present invention will be described in more detail by explaining the operation of the production apparatus 10 shown in FIGS. 1 and 2.
  • the first film 12 is pulled out from the first film roll 12R, wound around the backup roller 28, and passed through a predetermined conveyance path that reaches the take-up shaft through the peeling roller 36.
  • the second film 14 is pulled out from the second film roll 14R, wound around the backup roller 28 via the laminating roller 32, and passed through a predetermined transport path reaching the winding shaft via the peeling roller 36.
  • the coating device 30 is filled with a coating solution that becomes the coating film 40, that is, the cured layer 16.
  • the first film roll 12R, the second film roll 14R, the backup roller 28, the laminating roller 32, the peeling roller 36, and the illustration so that the conveyance speed of the first film 12 and the second film 14 becomes a predetermined speed.
  • the take-up shaft that is not rotated is rotated synchronously, and the conveyance of the first film 12 and the second film 14 is started. Thereafter, driving of the coating device 30 and the curing device 34 is started.
  • the first film 12 fed out from the first film roll 12R is coated with a coating material by the coating device 30 while being conveyed in the longitudinal direction while being wound around the backup roller 28, and the coating film 40 is formed on the surface.
  • the laminate having the coating film 40 formed on the surface of the first film 12 is then transported to the laminating position P and is transported in the longitudinal direction while being wound around the backup roller 28, while being pasted at the laminating position P.
  • the second film 14 delivered from the second film roll 14 ⁇ / b> R is laminated to the coating film 40 by the combined roller 32.
  • the laminate in which the coating film 40 is sandwiched between the first film 12 and the second film 14 is then conveyed to the curing device 34 and is conveyed in the longitudinal direction while being wound around the backup roller 28, while the curing device 34.
  • the active ray A is irradiated, the coating film 40 sandwiched between the first film 12 and the second film 14 is cured, and the cured layer 16 is formed.
  • the laminated film 20 is produced.
  • the laminated film 20 produced by forming the hardened layer 16 is peeled off from the backup roller 28 by the peeling roller 36, transported along a predetermined transport path, and taken up by a winding shaft.
  • the coating film 40 is formed by applying the coating liquid to the first film 12.
  • the first film 12 was wound around the backup roller 28 for the lamination of the second film 14 onto the coating film 40 and the curing of the coating film 40 sandwiched between the first film 12 and the second film 14. Do in state. Thereby, it can prevent that the film thickness of the coating film 40 produces a nonuniformity, and can manufacture the high quality laminated
  • Patent Document 1 and Patent Document 2 in the production of a conventional laminated film, the coating liquid is applied to the first film while the first film is nipped and conveyed by a roller pair or the like.
  • coating a coating liquid will be in the state which is floating in the air in the state which is not supported on anything. Therefore, in this floating region, a wave-like deformation occurs in the width direction of the first film 12 due to the tension applied to the first film 12.
  • the coating liquid for forming the coating film flows according to the deformation.
  • the film thickness of the coating film fluctuates due to the flow of the coating solution, and unevenness occurs in the film thickness of the coating film.
  • unevenness occurs in the film thickness of the formed cured layer. For this reason, it has been difficult to produce a laminated film with high uniformity of the thickness of the cured layer in the production of a conventional laminated film.
  • the formation of the coating film 40 on the first film 12, the lamination of the second film 14 on the coating film 40, and the first film 12 and the second film 14 Curing of the coating film 40 sandwiched between the two is performed in a state where the first film 12 is wound around the backup roller 28. Accordingly, the first film 12 is always supported by the backup roller 28 and does not cause a wave-like deformation. Thereby, the film thickness nonuniformity of the coating film 40 by the deformation
  • the coating film 40 and the second film 14 are always supported by the backup roller 28.
  • FIG. 3 an example of another aspect of the manufacturing apparatus of this invention is shown notionally.
  • FIG. 4 is a partially enlarged view of FIG.
  • the manufacturing apparatus 50 shown in FIGS. 3 and 4 has the same configuration as the above-described manufacturing apparatus 10 except that the positional relationship between the bonding roller 52 and the backup roller 28 is different. Accordingly, the same members are denoted by the same reference numerals, and the following description mainly focuses on different points.
  • the distance L1 between the backup roller 28 and the bonding roller 32 is equal to or greater than the sum of the thickness d1 of the first film 12, the thickness dc of the coating film 40, and the thickness d2 of the second film. It is. That is, as described above, “L1 ⁇ d1 + dc + d2”.
  • the distance L1 between the backup roller 28 and the bonding roller 32 is the thickness d1 of the first film 12, the thickness dc of the coating film 40, and the first Less than the sum of the thicknesses d2 of the two films. That is, in this aspect, “L1 ⁇ d1 + dc + d2”.
  • the second film 14 is in contact with the coating film 40 while being wound around the bonding roller 32, that is, the second film 14 is wound around the bonding roller at the lamination position P. ing.
  • the film thickness of the coating film 40 can be changed by pressing the coating film 40 with the second film 14 at the lamination position P. That is, in the manufacturing apparatus 50, the film thickness of the coating film 40 can be adjusted by adjusting the distance L1 between the backup roller 28 and the bonding roller 32.
  • the manufacturing apparatus 10 shown in FIG. 1 and FIG. 2 described above corresponds to the case where the coating apparatus 40 can form the coating film 40 having a uniform film thickness and having a desired film thickness with sufficient accuracy.
  • the manufacturing apparatus 50 shown in FIG. 3 and FIG. 4 is suitable for a case where the application liquid application control by the application apparatus 30 is not performed with high accuracy.
  • the formation of the coating film 40 on the first film 12 is all performed in a state where the first film 12 is wound around the backup roller 28. There is no unevenness in the film thickness of the coating film 40 due to the deformation of 12. Therefore, the film thickness adjustment of the coating film 40 by pressing the second film 14 can be performed with very high accuracy.
  • the manufacturing apparatus 50 when the second film 14 is laminated on the coating film 40, it is possible to prevent air (gas) from being caught between the coating film 40 and the second film 14. In other words, this aspect can be suitably handled even when air entrainment between the coating film 40 and the second film 14 becomes a problem, depending on the device configuration and the like.
  • L1 ⁇ d1 + dc + d2 may be satisfied according to the film thickness of the coating film 40 and the target film thickness of the cured layer 16.
  • the thickness of the coating film 40 may be appropriately set according to the film thickness of the cured layer 16 and the like, similar to the manufacturing apparatus 10 described above.
  • the film thickness of the preferable coating film 40 is also the same. If the adjustment amount of the thickness of the coating film 40 is also set appropriately according to the film thickness of the cured layer 16, the accuracy of the film thickness of the coating film 40, the film thickness of the coating film 40 before adjusting the thickness, and the like. Good.
  • Example 1 As the first film 12 and the second film 14, a PET film having a thickness of 100 ⁇ m and a width of 1000 mm (manufactured by Toyobo Co., Ltd., Cosmo Shine A4300) was prepared. Moreover, the following coating liquid was prepared as a coating liquid which a coating device apply
  • Quantum dot 1 INP530-10 (manufactured by NN-labs)
  • Quantum dot 2 INP620-10 (manufactured by NN-labs)
  • a laminated film 20 was produced by the production apparatus 10 shown in FIG.
  • the backup roller 28 is made of stainless steel having a diameter of 200 mm, which incorporates temperature adjusting means, and the surface temperature was adjusted to 25 ° C.
  • the conveyance speed of the first film 12 was 1 m / min, and the tension applied to the first film 12 and the second film 14 was 100 N / m.
  • the film thickness of the coating film 40 was 70 micrometers. Therefore, in this example, the thickness of the hardened layer 16 is approximately 70 ⁇ m.
  • the distance L1 between the backup roller and the bonding roller was 10 mm.
  • an LED UV-LED 233A, manufactured by Sentec Co., Ltd.
  • UV-LED 233A UV-LED 233A, manufactured by Sentec Co., Ltd.
  • the irradiation amount of ultraviolet rays was set to 900 mJ / cm 2 .
  • [T2 / (E2 ⁇ d2)] / [T1 / (E1 ⁇ d1)] was 1.
  • Example 2 except that the lamination of the second film 14 and the curing of the coating film were performed while the first film 12 was removed from the backup roller 28 and then separately conveyed by a pair of rollers arranged downstream of the backup roller 28.
  • a laminated film was produced in the same manner as in 1.
  • Example 2 As the light source of the curing device 34, a metal halide lamp (M30-L51X, manufactured by Eye Graphics Co., Ltd.) that irradiates ultraviolet rays having a center wavelength of 365 nm was used instead of the LED.
  • This light source has a main light emission wavelength region of 200 to 450 nm and a wide light emission wavelength width, so that the half-value width exceeds 100 nm.
  • a laminated film 20 was produced in the same manner as in Example 1 except that the above light source was used, the irradiation amount of ultraviolet rays was 900 mJ / cm 2, and the surface temperature of the backup roller 28 was 55 ° C.
  • Example 3 A laminated film 20 was produced in the same manner as in Example 1 except that the light source was used, the irradiation amount of ultraviolet rays was 50 mJ / cm 2, and the surface temperature of the backup roller 28 was 25 ° C.
  • Example 4> A laminated film 20 was produced in the same manner as in Example 1 except that the tension of the second film 14 was 10 N / m. [T2 / (E2 ⁇ d2)] / [T1 / (E1 ⁇ d1)] was 0.1.
  • Example 5> A laminated film 20 was produced in the same manner as in Example 1 except that the tension of the second film 14 was 200 N / m. [T2 / (E2 ⁇ d2)] / [T1 / (E1 ⁇ d1)] was 2.
  • Example 6> A laminated film 20 was produced in the same manner as in Example 1 except that the tension of the second film 14 was 1000 N / m.
  • Example 7 A laminated film 20 was produced in the same manner as in Example 1 except that the tension of the second film 14 was changed to 5 N / m. [T2 / (E2 ⁇ d2)] / [T1 / (E1 ⁇ d1)] was 0.05. ⁇ Example 8> A laminated film 20 was produced in the same manner as in Example 1 except that the tension of the first film 12 was 50 N / m and the tension of the second film 14 was 1000 N / m. [T2 / (E2 ⁇ d2)] / [T1 / (E1 ⁇ d1)] was 20.
  • Example 9 A laminated film 20 was produced in the same manner as in Example 1 except that the manufacturing apparatus 50 shown in FIGS. 3 and 4 in which the distance L1 between the backup roller and the bonding roller was 260 ⁇ m was used. Therefore, in this example, the thickness of the hardened layer 16 is 60 ⁇ m.
  • Example 2 A laminated film was produced in the same manner as in Example 1 except that the coating liquid was applied to the first film 12 before the first film 12 was wound around the backup roller.
  • the film thickness of the produced laminated film is measured with a contact-type thickness measuring device (manufactured by Yamabun Electric Co., Ltd., TOF5R), and the film thicknesses of the first film 12 and the second film 14 are determined from the measurement results of the film thickness of the laminated film.
  • the film thickness of the cured layer 16 was measured.
  • the film thickness of the cured layer 16 is measured at 1000 points at 1 mm intervals in the film transport direction and in the direction orthogonal to the film transport direction, and the thickness unevenness is determined from the minimum film thickness and the maximum film thickness with respect to the average film thickness.
  • the direction orthogonal to the conveyance direction of a film is the width direction of a film.
  • a film having a thickness unevenness of ⁇ 3% or more was evaluated as C; The results are shown in the table below.
  • Comparative Example 1 in which the second film 14 is laminated and the coating film is cured in a state of being detached from the backup roller 28, and Comparative Example in which the coating film is formed before being wound around the backup roller 28.
  • the thickness unevenness of the hardened layer exceeds 3%.
  • the lamination of the second film 14 and the curing of the coating film are all performed by winding the first film 12 around the backup roller 28, the thickness unevenness of the cured layer 16 is increased. Can be suppressed.
  • the tension applied to the second film is 100 N / m or less
  • the half width of the active line for curing the coating film 40 is 100 nm or less
  • the backup roller 28 By satisfying all the conditions that the surface temperature is 55 ° C. or less, a laminated film having a thickness unevenness of the cured layer 16 of less than ⁇ 2% and a very small thickness unevenness of the cured layer 16 can be obtained. Even if the evaluation of the thickness unevenness is “B”, the thickness unevenness is less than ⁇ 3%, so that there is no problem in practical use if it is normal.

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Abstract

The present invention addresses the problem of providing a method and device for manufacturing a layered film, whereby a layered film having a uniform thickness of a cured layer is obtained in the manufacturing of a layered film in which a cured layer obtained by curing an active-ray-curable resin is sandwiched between two films. The abovementioned problem is solved by performing, in a state in which a first film is wound onto a backup roller, all of a coating film forming step for forming a coating film of a coating liquid including an active-ray-curable resin on a surface of a first film while continuously conveying the first film, a laminating step for laminating a second film on the coating film while continuously conveying the second film, and a curing step for radiating active rays and forming a cured layer of the coating film while continuously conveying the coating film in a state in which the coating film is sandwiched between the first film and the second film.

Description

積層フィルムの製造方法および積層フィルムの製造装置LAMINATED FILM MANUFACTURING METHOD AND LAMINATED FILM MANUFACTURING DEVICE
　本発明は、硬化層をフィルムで挟持した、積層フィルムの製造に関する。 The present invention relates to the production of a laminated film in which a cured layer is sandwiched between films.
　光学素子、液晶ディスプレイや有機ＥＬディスプレイなどの表示装置、半導体装置、薄膜太陽電池等の各種の装置に、ガスバリアフィルム、保護フィルム、光学フィルタ、反射防止フィルム、量子ドットフィルムなどの各種のフィルムが利用されている。 Various devices such as gas barrier films, protective films, optical filters, antireflection films, and quantum dot films are used in various devices such as optical devices, display devices such as liquid crystal displays and organic EL displays, semiconductor devices, and thin film solar cells. Has been.
　これらのフィルムとして、目的とする機能を発現する複数のフィルムや層を積層して構成される積層フィルムが知られている。
　例えば、量子ドットフィルムは、一例として、量子ドットを樹脂に分散して硬化した量子ドット層を、２枚のフィルムで挟持してなる構成を有する。また、量子ドット層を挟持するフィルムとしては、酸素等による量子ドットの劣化を防止するためにガスバリアフィルム等が利用されている。 As these films, a laminated film constituted by laminating a plurality of films and layers that express a target function is known.
For example, a quantum dot film has a configuration in which a quantum dot layer obtained by dispersing and curing quantum dots in a resin is sandwiched between two films as an example. In addition, as a film for sandwiching the quantum dot layer, a gas barrier film or the like is used in order to prevent deterioration of the quantum dot due to oxygen or the like.
　積層フィルムの製造方法として種々の方法が提案されている。
　例えば、特許文献１には、成型用基体に電子線硬化型樹脂組成物を塗布して硬化することで硬化層を形成し、他方で、シート状基体に電子線硬化型樹脂組成物からなる塗膜（塗布層）を形成し、硬化層と塗膜とを対面して成型用基体とシート状基体とを積層し、この積層体に電子線等を照射して塗膜を硬化して硬化層を形成した後、成型用基体から硬化層、硬化層およびシート状基体を積層してなる積層フィルムを剥離する、積層フィルムの製造方法が記載されている。
　成型用支持体としては、円筒状のドラムや成型用フィルム等が例示されている。 Various methods have been proposed as a method for producing a laminated film.
For example, in Patent Document 1, a cured layer is formed by applying and curing an electron beam curable resin composition on a molding substrate, and, on the other hand, a coating made of an electron beam curable resin composition on a sheet substrate. A film (coating layer) is formed, and the cured layer and the coating film are faced to laminate a molding substrate and a sheet-like substrate, and this coating is cured by irradiating an electron beam or the like to the cured layer. A method for producing a laminated film is described, in which a laminated film formed by laminating a cured layer, a cured layer and a sheet-like substrate is peeled off from the molding substrate.
Examples of the molding support include a cylindrical drum and a molding film.
　また、特許文献２には、供給手段から送り出した第１のシートの表面に、紫外線硬化樹脂を塗布する塗布工程と、第１の紫外線硬化手段で紫外線硬化樹脂を部分硬化させる第１の硬化工程と、厚さを制御するコッターを備えた圧着手段によって、供給手段から送り出された第２のシートを第１のシートに対して貼り合わせて長尺積層物とする圧着工程と、第２の紫外線硬化手段により、紫外線硬化樹脂をさらに硬化させる第２の硬化工程とを含み、かつ、第２の紫外線硬化手段による紫外線照射量を、第１の紫外線硬化手段による紫外線照射量よりも大きくする積層フィルムの製造方法が記載されている。 Patent Document 2 discloses an application step of applying an ultraviolet curable resin to the surface of the first sheet fed from the supply unit, and a first curing step of partially curing the ultraviolet curable resin by the first ultraviolet curing unit. And a pressure bonding step including a cotter for controlling the thickness, a second pressure sheet that is bonded to the first sheet by the second sheet fed from the supply means to form a long laminate, and a second ultraviolet ray A laminated film including a second curing step of further curing the ultraviolet curable resin by the curing means, and making the ultraviolet irradiation amount by the second ultraviolet curing means larger than the ultraviolet irradiation amount by the first ultraviolet curing means The manufacturing method is described.
特開平１０－１１４０４１号公報JP-A-10-114041 特開２０１１－２２５００２号公報JP 2011-225002 A
　これらの製造方法によれば、いわゆるロール・トゥ・ロールを利用して、良好な生産効率で硬化層をフィルムで挟持した積層フィルムを製造できる。
　しかしながら、特許文献１および特許文献２に記載されるような従来の積層フィルムの製造方法では、硬化層の厚さにムラが生じ易い。そのため、硬化層の厚さに高い均一性が要求される用途では、目的とする積層フィルムの製造は困難である。 According to these production methods, it is possible to produce a laminated film in which a cured layer is sandwiched between films with good production efficiency using so-called roll-to-roll.
However, in the conventional method for producing a laminated film as described in Patent Document 1 and Patent Document 2, unevenness tends to occur in the thickness of the cured layer. For this reason, it is difficult to produce a desired laminated film in applications that require high uniformity in the thickness of the cured layer.
　本発明の目的は、このような従来技術の問題点を解決することにあり、硬化層をフィルムで挟持してなる積層フィルムの製造において、硬化層の厚さムラを大幅に抑制して、硬化層の厚さの均一性が高い積層フィルムを製造できる積層フィルムの製造方法および製造装置を提供することにある。 An object of the present invention is to solve such problems of the prior art, and in the production of a laminated film in which a cured layer is sandwiched between films, the thickness unevenness of the cured layer is greatly suppressed and cured. It is providing the manufacturing method and manufacturing apparatus of a laminated film which can manufacture the laminated film with the high uniformity of the thickness of a layer.
　このような目的を達成するために、本発明の積層フィルムの製造方法は、第１のフィルムを連続搬送しつつ、第１のフィルムの表面に活性線硬化型樹脂を含む塗布液を塗布し、塗膜を形成する塗膜形成工程と、
　第２のフィルムを連続搬送しつつ、第２のフィルムを塗膜の上にラミネートするラミネート工程と、
　第１のフィルムと第２のフィルムとで塗膜を挟持して連続搬送しつつ、活性線を照射し、塗膜を硬化させて硬化層を形成する硬化工程と、を有し、かつ、
　塗膜形成工程、ラミネート工程および硬化工程を、全て、第１のフィルムをバックアップローラに巻き掛けた状態で行うことを特徴とする積層フィルムの製造方法を提供する。 In order to achieve such an object, the method for producing a laminated film of the present invention applies a coating solution containing an actinic radiation curable resin to the surface of the first film while continuously conveying the first film, A coating film forming step for forming a coating film;
A laminating step of laminating the second film on the coating film while continuously conveying the second film;
A curing step of forming a cured layer by irradiating actinic radiation, curing the coating film while continuously transporting the coating film sandwiched between the first film and the second film, and
Provided is a method for producing a laminated film, wherein the coating film forming step, the laminating step, and the curing step are all performed in a state where the first film is wound around a backup roller.
　このような本発明の積層フィルムの製造方法において、ラミネート工程において、第２のフィルムを、第１のフィルムと離間する貼合ローラに巻き掛けて、塗膜の上にラミネートするのが好ましい。
　また、貼合ローラとバックアップローラとの距離が、第１のフィルムの厚さと塗膜の厚さと第２のフィルムの厚さとの合計以上であるのが好ましい。
　また、貼合ローラとバックアップローラとの距離が、第１のフィルムの厚さと塗膜の厚さと第２のフィルムの厚さとの合計未満であるのが好ましい。
　また、バックアップローラと貼合ローラとの間隙を調節して、貼合ローラに巻き掛けられる第２のフィルムによって塗膜の膜厚を調節するのが好ましい。
　また、第２のフィルムに掛かる張力が１００Ｎ／ｍ以下であるのが好ましい。
　また、硬化工程において、塗膜を硬化させる活性線が、波長に対する強度分布の半値幅が１００ｎｍ以下の電磁波であるのが好ましい。
　また、バックアップローラの表面温度を１５～５５℃に調節するのが好ましい。
　また、第１のフィルムに掛かる張力をＴ１、第１のフィルムの搬送方向のヤング率をＥ１、第１のフィルムの厚さをｄ１とし、第２のフィルムに掛かる張力をＴ２、第２のフィルムの搬送方向のヤング率をＥ２、第２のフィルムの厚さをｄ２とした際に、下記式
　０．０５＜［Ｔ２／（Ｅ２×ｄ２）］／［Ｔ１／（Ｅ１×ｄ１）］＜２０
を満たすのが好ましい。 In such a method for producing a laminated film of the present invention, in the laminating step, it is preferable that the second film is wound around a laminating roller separated from the first film and laminated on the coating film.
Moreover, it is preferable that the distance of a bonding roller and a backup roller is more than the sum total of the thickness of a 1st film, the thickness of a coating film, and the thickness of a 2nd film.
Moreover, it is preferable that the distance of a bonding roller and a backup roller is less than the sum total of the thickness of a 1st film, the thickness of a coating film, and the thickness of a 2nd film.
Moreover, it is preferable to adjust the film thickness of a coating film with the 2nd film wound around a bonding roller by adjusting the clearance gap between a backup roller and a bonding roller.
The tension applied to the second film is preferably 100 N / m or less.
Moreover, it is preferable that the active line which hardens a coating film in a hardening process is an electromagnetic wave whose half value width of intensity distribution with respect to a wavelength is 100 nm or less.
In addition, the surface temperature of the backup roller is preferably adjusted to 15 to 55 ° C.
Further, the tension applied to the first film is T1, the Young's modulus in the transport direction of the first film is E1, the thickness of the first film is d1, the tension applied to the second film is T2, and the second film The following formula 0.05 <[T2 / (E2 × d2)] / [T1 / (E1 × d1)] <20 where the Young's modulus in the transport direction is E2 and the thickness of the second film is d2.
It is preferable to satisfy.
　また、本発明の積層フィルムの製造装置は、バックアップローラと、
　第１のフィルムをバックアップローラに巻き掛けて連続搬送する搬送手段と、
　バックアップローラに対面して配置される、バックアップローラに巻き掛けられた第１のフィルムに、活性線硬化型樹脂を含む塗布液を塗布し、塗膜を形成する塗膜形成手段と、
　塗膜形成手段の第１のフィルムの搬送方向下流側に、バックアップローラに対面して配置される、第２のフィルムを連続搬送しつつ塗膜にラミネートするラミネート手段と、
　ラミネート手段の第１のフィルムの搬送方向下流側に、バックアップローラに対面して配置される、第１のフィルムおよび第２のフィルムで塗膜を挟持した積層体に活性線を照射する硬化手段と、を有することを特徴とする積層フィルムの製造装置を提供する。 The laminated film manufacturing apparatus of the present invention includes a backup roller,
A conveying means for continuously conveying the first film around the backup roller;
A coating film forming means for applying a coating liquid containing an actinic radiation curable resin to the first film wound around the backup roller, which is arranged facing the backup roller, and forming a coating film;
Laminating means for laminating the second film on the coating film while continuously conveying the second film, on the downstream side in the conveying direction of the first film of the coating film forming means,
Curing means for irradiating the laminated body sandwiching the coating film between the first film and the second film, which is disposed facing the backup roller, on the downstream side in the conveying direction of the first film of the laminating means; The manufacturing apparatus of the laminated film characterized by having these is provided.
　このような本発明によれば、硬化層をフィルムで挟持してなる積層フィルムの製造において、硬化層の厚さムラを大幅に抑制して、硬化層の厚さの均一性が高い積層フィルムを製造できる。 According to the present invention, in the production of a laminated film in which a cured layer is sandwiched between films, the thickness unevenness of the cured layer is greatly suppressed, and a laminated film with high uniformity of the thickness of the cured layer is obtained. Can be manufactured.
図１は、本発明の積層フィルムの製造装置の一例を概念的に示す図である。FIG. 1 is a diagram conceptually illustrating an example of a laminated film manufacturing apparatus of the present invention. 図２は、図１の部分拡大図である。FIG. 2 is a partially enlarged view of FIG. 図３は、本発明の積層フィルムの製造装置の別の例を概念的に示す図である。FIG. 3 is a diagram conceptually illustrating another example of the laminated film manufacturing apparatus of the present invention. 図４は、図３の部分拡大図である。FIG. 4 is a partially enlarged view of FIG.
　以下、本発明の積層フィルムの製造方法および積層フィルムの製造装置について、添付の図面に示される好適実施例を基に、詳細に説明する。
　以下に記載する構成要件の説明は、本発明の代表的な実施態様に基づいてなされることがあるが、本発明はそのような実施態様に限定されるものではない。
　なお、本明細書において、「～」を用いて表される数値範囲は、「～」の前後に記載される数値を下限値および上限値として含む範囲を意味する。 Hereinafter, the manufacturing method of a laminated film and the apparatus for producing a laminated film of the present invention will be described in detail based on preferred embodiments shown in the accompanying drawings.
The description of the constituent elements described below may be made based on typical embodiments of the present invention, but the present invention is not limited to such embodiments.
In this specification, a numerical range expressed using “to” means a range including numerical values described before and after “to” as a lower limit value and an upper limit value.
　図１に、本発明の積層フィルムの製造方法を実施する本発明の積層フィルムの製造装置の一例を概念的に示す。また、図２に、図１の部分拡大図を示す。
　図１に示す積層フィルムの製造装置１０は、第１のフィルム１２と第２のフィルム１４とで硬化層１６を挟持してなる積層フィルム２０を製造するものである。以下の説明では、『積層フィルムの製造装置１０』を『製造装置１０』、『第１のフィルム１２』を『第１フィルム１２』、『第２のフィルム１４』を『第２フィルム１４』とも言う。 In FIG. 1, an example of the manufacturing apparatus of the laminated film of this invention which enforces the manufacturing method of the laminated film of this invention is shown notionally. FIG. 2 shows a partially enlarged view of FIG.
A laminated film production apparatus 10 shown in FIG. 1 produces a laminated film 20 in which a cured layer 16 is sandwiched between a first film 12 and a second film 14. In the following description, “laminated film manufacturing apparatus 10” is referred to as “manufacturing apparatus 10”, “first film 12” as “first film 12”, and “second film 14” as “second film 14”. To tell.
　図示例の製造装置１０は、基本的に、第１フィルム１２を供給する第１供給部２４と、第２フィルム１４を供給する第２供給部２６と、バックアップローラ２８と、塗布装置３０と、貼合ローラ３２と、硬化装置３４と、剥離ローラ３６とを有して構成される。 The manufacturing apparatus 10 in the illustrated example basically includes a first supply unit 24 that supplies the first film 12, a second supply unit 26 that supplies the second film 14, a backup roller 28, a coating device 30, A laminating roller 32, a curing device 34, and a peeling roller 36 are included.
　製造装置１０は、長尺なフィルム（シート状物）を巻回してなるロールからフィルムを送り出し、フィルムを長手方向に搬送しつつ成膜等の処理を行い、処理済のフィルムをロール状に巻回する、いわゆるロール・トゥ・ロールによる製造装置である。
　具体的には、製造装置１０は、第１供給部２４から第１フィルム１２を送り出してバックアップローラ２８に巻き掛け、第１フィルム１２を長手方向に搬送しつつ、まず、塗布装置３０によって第１フィルム１２の表面に塗布液（塗料／塗布組成物）を塗布して塗膜４０を形成する。次いで、第２供給部２６から第２フィルム１４を送り出して、塗膜４０の表面に第２フィルム１４をラミネートする。次いで、硬化装置３４によって活性線Ａを照射して第１フィルム１２と第２フィルム１４とで挟持された塗膜４０を硬化して硬化層１６を形成して、積層フィルム２０を製造する。 The manufacturing apparatus 10 sends out a film from a roll formed by winding a long film (sheet-like material), performs film formation while conveying the film in the longitudinal direction, and winds the processed film into a roll. It is a so-called roll-to-roll manufacturing device that rotates.
Specifically, the manufacturing apparatus 10 sends out the first film 12 from the first supply unit 24, winds it around the backup roller 28, and transports the first film 12 in the longitudinal direction. A coating liquid 40 is formed by applying a coating liquid (paint / coating composition) to the surface of the film 12. Next, the second film 14 is sent out from the second supply unit 26, and the second film 14 is laminated on the surface of the coating film 40. Next, the actinic ray A is irradiated by the curing device 34 to cure the coating film 40 sandwiched between the first film 12 and the second film 14 to form the cured layer 16, thereby manufacturing the laminated film 20.
　ここで、本発明の積層フィルムの製造方法および製造装置は、第１フィルム１２の表面に塗膜４０を形成する塗膜形成工程、塗膜４０の上に第２フィルム１４をラミネートするラミネート工程、および、第１フィルム１２と第２フィルム１４とで挟持された塗膜４０を硬化する硬化工程を、全て、第１フィルム１２をバックアップローラ２８に巻き掛けた状態で、長手方向に搬送しつつ行う。 Here, the manufacturing method and the manufacturing apparatus of the laminated film of the present invention include a coating film forming process for forming the coating film 40 on the surface of the first film 12, a laminating process for laminating the second film 14 on the coating film 40, And all the hardening processes which harden the coating film 40 pinched | interposed by the 1st film 12 and the 2nd film 14 are performed in the state which wound the 1st film 12 around the backup roller 28, and conveyed in a longitudinal direction. .
　前述のように、第１供給部２４は、第１フィルム１２をバックアップローラ２８に供給する部位である。
　第１供給部２４は、回転軸２４ａを有する。この回転軸２４ａには、長尺な第１フィルム１２をロール状に巻回してなる第１フィルムロール１２Ｒが装填される。
　第１供給部２４においては、回転軸２４ａを回転することによって第１フィルムロール１２Ｒから第１フィルム１２を送り出す。第１供給部２４から送り出された第１フィルム１２は、バックアップローラ２８に巻き掛けられ、所定の経路を搬送される。
　なお、バックアップローラ２８に巻き掛けられる領域を含む、第１フィルム１２、第１フィルム１２と塗膜４０との積層体、第１フィルム１２と塗膜４０と第２フィルムとの積層体、および、積層フィルム２０の搬送は、公知の方法で行えばよい。 As described above, the first supply unit 24 is a part that supplies the first film 12 to the backup roller 28.
The 1st supply part 24 has the rotating shaft 24a. The rotating shaft 24a is loaded with a first film roll 12R formed by winding the long first film 12 into a roll shape.
In the 1st supply part 24, the 1st film 12 is sent out from the 1st film roll 12R by rotating the rotating shaft 24a. The first film 12 sent out from the first supply unit 24 is wound around the backup roller 28 and conveyed along a predetermined path.
The first film 12, the laminate of the first film 12 and the coating film 40, the laminate of the first film 12, the coating film 40, and the second film, including the region wound around the backup roller 28, and The transport of the laminated film 20 may be performed by a known method.
　本発明において、第１フィルム１２および第２フィルム１４は、公知の積層フィルムで利用されているフィルム（シート状物）が、各種、利用可能である。
　一例として、ポリエチレン（ＰＥ）、ポリエチレンナフタレート（ＰＥＮ）、ポリアミド（ＰＡ）、ポリエチレンテレフタレート（ＰＥＴ）、ポリ塩化ビニル（ＰＶＣ）、ポリビニルアルコール（ＰＶＡ）、ポリアクリトニトリル（ＰＡＮ）、ポリイミド（ＰＩ）、透明ポリイミド、ポリメタクリル酸メチル樹脂（ＰＭＭＡ）、ポリカーボネート（ＰＣ）、ポリアクリレート、ポリメタクリレート、ポリプロピレン（ＰＰ）、ポリスチレン（ＰＳ）、アクリロニトリル・ブタジエン・スチレン共重合体（ＡＢＳ）、環状オレフィン・コポリマー（ＣＯＣ）、シクロオレフィンポリマー（ＣＯＰ）、および、トリアセチルセルロース（ＴＡＣ）等の樹脂材料からなる樹脂フィルムが例示される。 In the present invention, as the first film 12 and the second film 14, various types of films (sheet-like materials) used in known laminated films can be used.
For example, polyethylene (PE), polyethylene naphthalate (PEN), polyamide (PA), polyethylene terephthalate (PET), polyvinyl chloride (PVC), polyvinyl alcohol (PVA), polyacrylonitrile (PAN), polyimide (PI) , Transparent polyimide, polymethyl methacrylate resin (PMMA), polycarbonate (PC), polyacrylate, polymethacrylate, polypropylene (PP), polystyrene (PS), acrylonitrile-butadiene-styrene copolymer (ABS), cyclic olefin copolymer Examples of the resin film include resin materials such as (COC), cycloolefin polymer (COP), and triacetyl cellulose (TAC).
　第１フィルム１２および第２フィルム１４は、少なくとも一方が、ガスバリアフィルムであるのが好ましい。
　ガスバリアフィルムとしては、一例として、支持体の表面に、ガスバリア性を発現するガスバリア層を形成してなるものが例示される。中でも、ガスバリア層として、ガスバリア性を発現する無機層と、この無機層の下地層となる有機層との組み合わせを、１組以上、形成してなるガスバリアフィルムは、好適に利用される。
　ガスバリア層やガスバリア性を発現する無機層としては、窒化ケイ素、酸化窒化ケイ素、酸化ケイ素、酸化アルミニウム等からなる層が、好適に例示される。
　また、下地となる有機層としては，ジプロピレングリコールジ（メタ）アクリレート（ＤＰＧＤＡ）、トリメチロールプロパントリ（メタ）アクリレート（ＴＭＰＴＡ）、ジペンタエリスリトールヘキサ（メタ）アクリレート（ＤＰＨＡ）などの、２官能以上、特に３官能以上のアクリレートおよび/またはメタクリレートのモノマやオリゴマの重合体を主成分とするアクリル樹脂やメタクリル樹脂が、好適に例示される。 At least one of the first film 12 and the second film 14 is preferably a gas barrier film.
As an example of the gas barrier film, a film obtained by forming a gas barrier layer exhibiting gas barrier properties on the surface of a support is exemplified. Among these, as the gas barrier layer, a gas barrier film formed by forming one or more combinations of an inorganic layer exhibiting gas barrier properties and an organic layer serving as a base layer of the inorganic layer is suitably used.
Preferred examples of the gas barrier layer and the inorganic layer exhibiting gas barrier properties include a layer made of silicon nitride, silicon oxynitride, silicon oxide, aluminum oxide, or the like.
Moreover, as an organic layer used as a foundation, bifunctional such as dipropylene glycol di (meth) acrylate (DPGDA), trimethylolpropane tri (meth) acrylate (TMPTA), dipentaerythritol hexa (meth) acrylate (DPHA), etc. As mentioned above, the acrylic resin and methacrylic resin which have as a main component the monomer and oligomer polymer of a trifunctional or more than trifunctional acrylate and / or methacrylate are illustrated suitably.
　第１フィルム１２および第２フィルム１４として、ガスバリアフィルムを用いることにより、硬化層１６が酸素や水分等で劣化することを防止できる。
　この点を考慮すると、第１フィルム１２および第２フィルム１４は、酸素透過率が１×１０-4～１cm3/(m2・day・atm）であるのが好ましい。
　酸素透過率は、一例として、温度２３℃、相対湿度９０％の条件下で、酸素ガス透過率測定装置（ＭＯＣＯＮ社製、ＯＸ－ＴＲＡＮ２／２０）を用いて測定すればよい。 By using a gas barrier film as the first film 12 and the second film 14, it is possible to prevent the cured layer 16 from being deteriorated by oxygen, moisture, or the like.
Considering this point, it is preferable that the first film 12 and the second film 14 have an oxygen permeability of 1 × 10 −4 to 1 cm 3 / (m 2 · day · atm).
For example, the oxygen transmission rate may be measured using an oxygen gas transmission rate measuring device (manufactured by MOCON, OX-TRAN 2/20) under the conditions of a temperature of 23 ° C. and a relative humidity of 90%.
　第１フィルム１２および第２フィルム１４は、少なくとも一方が、ハードコート層を有するのが好ましい。
　ここでハードコート層とは、耐傷性を有する層を意味し、引っかき硬度（鉛筆法）（ＪＩＳ　Ｋ－５６００（１９９９年）規格に準拠）（JIS:　Japanese Industrial Standards）がＨ以上である層を意味する。引っかき硬度は、２Ｈ以上がより好ましく、３Ｈ以上が特に好ましい。 At least one of the first film 12 and the second film 14 preferably has a hard coat layer.
Here, the hard coat layer means a layer having scratch resistance, and a layer having a scratch hardness (pencil method) (conforming to JIS K-5600 (1999) standard) (JIS: Japanese Industrial Standards) is H or more. means. The scratch hardness is more preferably 2H or more, and particularly preferably 3H or more.
　ハードコート層は、不飽和二重結合を有する化合物、重合開始剤、必要に応じて、透光性粒子、含フッ素またはシリコーン系化合物、有機溶媒を含有する組成物（ハードコート層形成材料物）を、塗布・乾燥・硬化することにより形成することができる。
　ハードコート層については、一例として、特開２０１４－１７０１３０号公報の段落［０１６２］～［０１８９］を参照できるが、これに限定はされない。 The hard coat layer is a composition containing a compound having an unsaturated double bond, a polymerization initiator, and, if necessary, translucent particles, a fluorine-containing or silicone compound, and an organic solvent (hard coat layer forming material). Can be formed by coating, drying and curing.
As an example of the hard coat layer, paragraphs [0162] to [0189] of JP-A No. 2014-170130 can be referred to, but the present invention is not limited thereto.
　第１フィルム１２および第２フィルム１４は、少なくとも一方が、光拡散層を有するのが好ましい。
　光拡散層とは、通過する光を散乱させる層を意味する。光拡散層は、透光性粒子、マトリックス形成成分（バインダー用モノマー類等）および有機溶媒を含有する塗布液を、塗布・乾 燥・硬化することにより形成することができる。
　光拡散層については、一例として、特開２００９－２５８７１６号公報の段落［００２５］～［００８９］を参照できるが、これに限定はされない。 At least one of the first film 12 and the second film 14 preferably has a light diffusion layer.
The light diffusion layer means a layer that scatters light passing therethrough. The light diffusing layer can be formed by coating, drying, and curing a coating liquid containing translucent particles, matrix-forming components (such as binder monomers) and an organic solvent.
As an example of the light diffusion layer, paragraphs [0025] to [0089] of JP-A-2009-258716 can be referred to, but the present invention is not limited thereto.
　第１フィルム１２および第２フィルム１４の厚さは、積層フィルム２０の用途等に応じて、適宜、設定すればよい。本発明者らの検討によれば、積層フィルム２０の厚さ低減硬化や、シワ防止の観点から、第１フィルム１２および第２フィルム１４の厚さは、１０～１００μｍが好ましく、１５～６０μｍがより好ましい。なお、第１フィルム１２および第２フィルム１４の厚さは、同じでも異なってもよい。
　第１フィルム１２および第２フィルム１４の厚さは、積層フィルム２０の用途等に応じて、適宜、設定すればよい。 What is necessary is just to set the thickness of the 1st film 12 and the 2nd film 14 suitably according to the use etc. of the laminated | multilayer film 20. FIG. According to the study by the present inventors, the thickness of the first film 12 and the second film 14 is preferably 10 to 100 μm, and preferably 15 to 60 μm, from the viewpoint of reducing the thickness of the laminated film 20 and preventing wrinkles. More preferred. Note that the thicknesses of the first film 12 and the second film 14 may be the same or different.
What is necessary is just to set the thickness of the 1st film 12 and the 2nd film 14 suitably according to the use etc. of the laminated | multilayer film 20. FIG.
　なお、本発明において、第１フィルム１２と第２フィルム１４とは、同じでも異なってもよい。
　すなわち、一例として、第１フィルム１２および第２フィルム１４は、同じガスバリアフィルムであってもよく、同じ樹脂フィルムであってもよく、異なるガスバリアフィルムであってもよく、異なる樹脂フィルムであってもよく、ガスバリアフィルムと樹脂フィルムであってもよい。
　ただし、いずれの場合あっても、本発明においては、少なくとも第２フィルム１４は、硬化装置３４が照射する活性線Ａを十分に透過するものである必要がある。 In the present invention, the first film 12 and the second film 14 may be the same or different.
That is, as an example, the first film 12 and the second film 14 may be the same gas barrier film, the same resin film, different gas barrier films, or different resin films. It may be a gas barrier film and a resin film.
However, in any case, in the present invention, at least the second film 14 needs to sufficiently transmit the actinic radiation A irradiated by the curing device 34.
　前述のように、第１供給部２４から送り出された第１フィルム１２は、バックアップローラ２８に巻き掛けられる。 As described above, the first film 12 sent out from the first supply unit 24 is wound around the backup roller 28.
　バックアップローラ２８は、例えば金属製の円筒状の部材で、円筒の側面に第１フィルム１２を巻き掛けて回転する。
　バックアップローラ２８に巻きかけるとは、第１フィルム１２が、あるラップ角でバックアップローラ２８の表面に接触している状態をいう。したがって、連続搬送される間、第１フィルム１２、あるいはさらに塗膜４０、あるいはさらに第２フィルム１４は、バックアップローラ２８の回転と同期して移動する。
　前述のように、本発明においては、第１フィルム１２への塗膜４０の形成、塗膜４０への第２フィルム１４のラミネート、塗膜４０の硬化は、全て、第１フィルム１２をバックアップローラ２８に巻き掛けた状態で行う。従って、バックアップローラ２８への第１フィルム１２の巻き掛けは、少なくとも、第１フィルム１２への塗膜４０の形成位置よりも上流の位置から、活性線Ａの照射位置よりも下流の位置までとなる。
　なお、本発明において、上流および下流とは、いずれも、第１フィルム１２の搬送方向の上流および下流である。 The backup roller 28 is a cylindrical member made of metal, for example, and rotates with the first film 12 wound around the side surface of the cylinder.
Wrapping around the backup roller 28 means a state in which the first film 12 is in contact with the surface of the backup roller 28 at a certain wrap angle. Therefore, during the continuous conveyance, the first film 12, or the coating film 40, or the second film 14 moves in synchronization with the rotation of the backup roller 28.
As described above, in the present invention, the formation of the coating film 40 on the first film 12, the lamination of the second film 14 on the coating film 40, and the curing of the coating film 40 are all performed by using the backup roller for the first film 12. 28. Therefore, the first film 12 is wound around the backup roller 28 from at least a position upstream from the position where the coating film 40 is formed on the first film 12 to a position downstream from the irradiation position of the active ray A. Become.
In the present invention, upstream and downstream are both upstream and downstream in the transport direction of the first film 12.
　バックアップローラ２８は、好ましい態様として、バックアップローラ２８の表面温度を調節するための温度調節手段を内蔵する。なお、温度調節手段は、温度調節媒体の循環、ヒータや冷却手段を用いる方法等、公知の方法が、各種、利用可能である。 The backup roller 28 incorporates a temperature adjusting means for adjusting the surface temperature of the backup roller 28 as a preferred mode. As the temperature adjusting means, various known methods such as circulation of a temperature adjusting medium, a method using a heater or a cooling means can be used.
　積層フィルム２０の製造時には、好ましくは、バックアップローラ２８の表面温度を１５～５５℃に調節するのが好ましく、２０～４０℃に調節するのがより好ましい。
　本発明においては、塗膜４０を形成した後、塗膜４０の上に第２フィルムをラミネートした後に、活性線Ａを照射して、塗膜４０を硬化して硬化層１６とする。この際に、第１フィルム１２や第２フィルム１４が加熱されて、変形する可能性がある。塗膜４０の硬化時に第１フィルム１２や第２フィルム１４が変形すると、この変形に起因して、硬化層１６の厚さが変動し、硬化層１６に厚さムラが生じてしまう。
　バックアップローラ２８の温度を５５℃以下に調節することにより、加熱に起因する第１フィルム１２や第２フィルム１４の変形を好適に防止して、硬化層１６の膜厚のムラを防止できる。
　また、バックアップローラ２８の温度を１５℃以上とすることにより、冷却設備投資やランニングコストを低減できる等の点で好ましい。 When the laminated film 20 is manufactured, the surface temperature of the backup roller 28 is preferably adjusted to 15 to 55 ° C, more preferably 20 to 40 ° C.
In the present invention, after the coating film 40 is formed, the second film is laminated on the coating film 40, and then the active ray A is irradiated to cure the coating film 40 to form the cured layer 16. At this time, the first film 12 and the second film 14 may be heated and deformed. If the first film 12 or the second film 14 is deformed when the coating film 40 is cured, the thickness of the cured layer 16 varies due to the deformation, and thickness unevenness occurs in the cured layer 16.
By adjusting the temperature of the backup roller 28 to 55 ° C. or less, the deformation of the first film 12 and the second film 14 due to heating can be suitably prevented, and unevenness in the thickness of the cured layer 16 can be prevented.
In addition, it is preferable to set the temperature of the backup roller 28 to 15 ° C. or higher from the viewpoint of reducing cooling equipment investment and running cost.
　バックアップローラ２８の直径は、製造装置１０のサイズ等に応じて、適宜、設定すればよい。
　本発明者らの検討によれば、積層フィルムのカール変形、設備コスト、回転精度等を考慮すると、バックアップローラの直径は１００～１０００ｍｍが好ましく、２００～５００ｍｍがより好ましい。 The diameter of the backup roller 28 may be set as appropriate according to the size of the manufacturing apparatus 10 and the like.
According to studies by the present inventors, the diameter of the backup roller is preferably 100 to 1000 mm, more preferably 200 to 500 mm, taking into account curled deformation of the laminated film, equipment cost, rotational accuracy, and the like.
　製造装置１０は、第１フィルム１２をバックアップローラ２８に巻き掛けた状態で、長手方向に搬送しつつ、まず、バックアップローラ２８に対面して位置される塗布装置３０によって、第１フィルム１２の表面に活性線硬化型樹脂を含む塗布液を塗布して、塗膜４０を形成する塗膜形成工程を行う。 The manufacturing apparatus 10 first transports the first film 12 around the backup roller 28 in the longitudinal direction while first transporting the surface of the first film 12 by the coating device 30 positioned facing the backup roller 28. The coating liquid formation process which forms the coating film 40 by apply | coating the coating liquid containing active ray curable resin to is performed.
　塗布装置３０は、塗布する塗布液に応じて、目的とする膜厚の塗膜４０を形成可能なものであれば、公知の液体の塗布装置が、各種、利用可能である。
　一例として、ダイコート法、カーテンコート法、ロッドコート法、エアーナイフコート法、カーテンコート法、ローラーコート法、ワイヤーバーコート法、グラビアコート法、スライドコート法等によって塗布液を塗布する塗布装置が例示される。 As the coating device 30, various known liquid coating devices can be used as long as they can form the coating film 40 having a target film thickness in accordance with the coating solution to be coated.
Examples include coating devices that apply coating solutions by die coating, curtain coating, rod coating, air knife coating, curtain coating, roller coating, wire bar coating, gravure coating, slide coating, etc. Is done.
　塗膜４０の膜厚は、硬化層１６の膜厚に応じて、適宜、設定すればよい。また、硬化層１６の膜厚は、積層フィルム２０の用途、硬化層１６の形成材料、硬化層１６が発現する作用、硬化層１６に要求される性能等に応じて、適宜、設定すればよい。
　本発明者の検討によれば、塗膜４０の膜厚は、１０～８０μｍが好ましい。 What is necessary is just to set the film thickness of the coating film 40 suitably according to the film thickness of the hardened layer 16. FIG. The film thickness of the cured layer 16 may be appropriately set according to the use of the laminated film 20, the material for forming the cured layer 16, the action of the cured layer 16, the performance required for the cured layer 16, and the like. .
According to the study of the present inventor, the film thickness of the coating film 40 is preferably 10 to 80 μm.
　塗膜４０すなわち硬化層１６となる塗布液は、活性線硬化型樹脂を含んでいる。
　活性線硬化型樹脂とは、活性線を照射することで架橋反応、重合反応を経て硬化する樹脂をいう。活性線とは、紫外線、電子線、放射線（α線、β線、γ線等）などの電磁波をいう。
　活性線硬化型樹脂として、例えば、光（紫外線）、電子線、放射線硬化性の多官能モノマーや多官能オリゴマーの官能基を有する 樹脂が使用され、中でも光重合性官能基が好ましい。光重合性官能基としては、（メタ）アクリロイル基、ビニル基、スチリル基、アリル基等の不飽和の重合性官能基等が挙げられる。 The coating liquid that becomes the coating film 40, that is, the cured layer 16 contains an actinic radiation curable resin.
The actinic radiation curable resin refers to a resin that is cured through a crosslinking reaction and a polymerization reaction when irradiated with actinic radiation. Actinic rays refer to electromagnetic waves such as ultraviolet rays, electron beams, and radiation (α rays, β rays, γ rays, etc.).
As the actinic radiation curable resin, for example, a resin having a functional group of light (ultraviolet ray), electron beam, radiation curable polyfunctional monomer or polyfunctional oligomer is used, and among them, a photopolymerizable functional group is preferable. Examples of the photopolymerizable functional group include unsaturated polymerizable functional groups such as a (meth) acryloyl group, a vinyl group, a styryl group, and an allyl group.
　塗布液の溶媒としては、例えば、有機溶媒を用いることができる。有機溶媒として、アルコール類、ケトン類、エステル類、脂肪族炭化水素類、アミド類、エーテル類、エーテルアルコール類が含まれる。これらの溶媒は２種以上を併用して用いるのが好ましく、３種以上併用して用いることがより好ましい。 As the solvent of the coating solution, for example, an organic solvent can be used. Examples of the organic solvent include alcohols, ketones, esters, aliphatic hydrocarbons, amides, ethers, and ether alcohols. These solvents are preferably used in combination of two or more, more preferably in combination of three or more.
　塗布液の粘度は、塗布液の組成、塗膜４０の厚さ等に応じて、適宜、設定すればよい。
　本発明者らの検討によれば、気泡の混入防止、および、塗膜４０の厚さの均一性の点から、塗布液の粘度は２０～６００ｍＰａ・ｓが好ましく４０～４００ｍＰａ・ｓがより好ましい。 What is necessary is just to set the viscosity of a coating liquid suitably according to the composition of a coating liquid, the thickness of the coating film 40, etc. FIG.
According to the study by the present inventors, the viscosity of the coating solution is preferably 20 to 600 mPa · s, and more preferably 40 to 400 mPa · s, from the viewpoint of preventing mixing of bubbles and the uniformity of the thickness of the coating film 40. .
　塗布液には、活性線硬化型樹脂に加えて、量子ドット、有機エレクトロルミネンッセンス材料、有機半導体材料、光電変換材料、熱電変換材料、染料や顔料など、各種の機能を発現する物質を加えてもよい。
　中でも、量子ドットは、好適に利用される。 In addition to actinic radiation curable resin, the coating solution contains substances that exhibit various functions such as quantum dots, organic electroluminescent materials, organic semiconductor materials, photoelectric conversion materials, thermoelectric conversion materials, dyes and pigments. May be.
Among these, quantum dots are preferably used.
　量子ドットとは、量子閉じ込め効果による光学特性を有する、粒径がナノスケールの結晶粒子をいう。
　量子ドットとして、例えば、コア－シェル構造の量子ドットが知られている。コア－シェル構造の量子ドットとしては、コア／シェルとすると、ＣｄＳｅ／ＺｎＳ、ＣｄＳｅ／ＣｄＳ、ＣｄＴｅ／ＣｄＳ、ＩｎＰ／ＺｎＳ、ＧａＰ／ＺｎＳ、Ｓｉ／ＺｎＳ、ＩｎＮ／ＧａＮ等が挙げられる。ただし、量子ドットの構造はコア－シェル構造に限定されない。
　量子ドットは、その大きさを変更することにより、光学特性を変更できる。量子ドットの粒子径が小さくなるほど、量子ドットが発光するエネルギーは大きくなる。また、量子ドットの発光波長は、通常、粒子の組成、サイズにより調整することができる。
　量子ドットについては、一例として、特開２０１２－１６９２７１号公報の段落［００６０］～［００６６］を参照することができるが、これに限定はされない。 A quantum dot refers to a crystal particle having a nanoscale particle size and having optical characteristics due to a quantum confinement effect.
For example, a quantum dot having a core-shell structure is known as a quantum dot. Examples of the core-shell quantum dots include CdSe / ZnS, CdSe / CdS, CdTe / CdS, InP / ZnS, GaP / ZnS, Si / ZnS, and InN / GaN. However, the quantum dot structure is not limited to the core-shell structure.
The quantum dot can change its optical characteristics by changing its size. The smaller the particle size of the quantum dots, the greater the energy emitted by the quantum dots. In addition, the emission wavelength of the quantum dots can usually be adjusted by the composition and size of the particles.
Regarding quantum dots, for example, paragraphs [0060] to [0066] of JP2012-169271A can be referred to, but the present invention is not limited thereto.
　また、量子ドットに代えて、量子ロッドを用いてもよい。量子ロッドとは、量子ドットと同様の特性を有し、細長い形状の粒子をいう。
　量子ドットとしては、市販品を何ら制限なく用いることができる。
　また、量子ドットと量子ロッドとを同時に使用することもできる。 Further, instead of quantum dots, quantum rods may be used. Quantum rods have the same characteristics as quantum dots and refer to elongated particles.
As the quantum dots, commercially available products can be used without any limitation.
Moreover, a quantum dot and a quantum rod can also be used simultaneously.
　硬化層１６が量子ドットおよび量子ロッドの少なくとも一方を含む積層フィルムは、量子ドットフィルムとも称される。 The laminated film in which the cured layer 16 includes at least one of quantum dots and quantum rods is also referred to as a quantum dot film.
　塗布装置３０の下流には、バックアップローラ２８に対面して、第２フィルム１４を塗膜４０にラミネートするための貼合ローラ３２が配置される。
　製造装置１０においては、第１フィルム１２の表面に塗膜４０を形成した積層体は、次いで、ラミネート工程で、貼合ローラ３２によるラミネート位置Ｐに搬送され、第２供給部２６から供給された第２フィルム１４が、貼合ローラ３２に巻き掛けられて所定の搬送経路に案内され、塗膜４０にラミネートされる。 A laminating roller 32 for laminating the second film 14 on the coating film 40 is disposed downstream of the coating device 30 so as to face the backup roller 28.
In the manufacturing apparatus 10, the laminate in which the coating film 40 is formed on the surface of the first film 12 is then conveyed to the laminating position P by the laminating roller 32 and supplied from the second supply unit 26 in the laminating process. The second film 14 is wound around the laminating roller 32, guided to a predetermined conveyance path, and laminated on the coating film 40.
　第２供給部２６は、回転軸２６ａを有する。この回転軸２６ａには、長尺な第２フィルム１４をロール状に巻回してなる第２フィルムロール１４Ｒが装填される。
　第２供給部２６においては、回転軸２６ａを回転することによって第２フィルムロール１４Ｒから第２フィルム１４を送り出す。第２供給部２６から送り出された第２フィルム１４は、貼合ローラ３２に巻き掛けられて、所定の経路を搬送されて、ラミネート位置Ｐにおいて、塗膜４０にラミネート（積層）される。 The 2nd supply part 26 has the rotating shaft 26a. A second film roll 14R formed by winding the long second film 14 into a roll shape is loaded on the rotating shaft 26a.
In the 2nd supply part 26, the 2nd film 14 is sent out from the 2nd film roll 14R by rotating the rotating shaft 26a. The second film 14 delivered from the second supply unit 26 is wound around the laminating roller 32, conveyed along a predetermined path, and laminated (laminated) on the coating film 40 at the laminating position P.
　ここで、図示例の製造装置１０においては、バックアップローラ２８の表面と貼合ローラ３２の表面との最短距離である距離Ｌ１が、第１フィルム１２の厚さｄ１と、塗膜４０の厚さｄｃと、第２フィルムの厚さｄ２との合計以上である。以下の説明では、距離Ｌ１を、『バックアップローラ２８と貼合ローラ３２との距離Ｌ１』とも言う。
　すなわち、『Ｌ１≧ｄ１＋ｄｃ＋ｄ２』である。
　言い換えれば、貼合ローラ３２に巻き掛かっている状態では第２フィルム１４は塗膜４０に接触しておらず、すなわち、ラミネート位置Ｐでは第２フィルム１４は貼合ローラに巻き掛かっていない。 Here, in the manufacturing apparatus 10 in the illustrated example, the distance L1 that is the shortest distance between the surface of the backup roller 28 and the surface of the bonding roller 32 is the thickness d1 of the first film 12 and the thickness of the coating film 40. It is more than the sum of dc and the thickness d2 of the second film. In the following description, the distance L1 is also referred to as “distance L1 between the backup roller 28 and the bonding roller 32”.
That is, “L1 ≧ d1 + dc + d2”.
In other words, the second film 14 is not in contact with the coating film 40 in a state where it is wound around the bonding roller 32, that is, the second film 14 is not wound around the bonding roller at the lamination position P.
　製造装置１０は、このような構成を有することにより、貼合ローラ３２が塗膜４０を押圧することなく、かつ、第２フィルム１４も塗膜４０を押圧することなく、極めて緩やかかつ穏やかに、塗膜４０に第２フィルム１４をラミネートできる。従って、塗膜４０に第２フィルム１４をラミネートしても、第２フィルム１４のラミネートに起因して塗膜４０の膜厚が変動することを防止できる。
　そのため、製造装置１０によれば、塗布装置３０によって、目的とする膜厚を有し、かつ、膜厚が均一な、高精度な塗膜４０を形成すれば、目的とする膜厚を有する、膜厚が均一な硬化層１６を作製できる。 The manufacturing apparatus 10 has such a configuration, so that the laminating roller 32 does not press the coating film 40, and the second film 14 also does not press the coating film 40. The second film 14 can be laminated on the coating film 40. Therefore, even if the second film 14 is laminated on the coating film 40, it is possible to prevent the film thickness of the coating film 40 from fluctuating due to the lamination of the second film 14.
Therefore, according to the manufacturing apparatus 10, if the coating apparatus 30 has a target film thickness and has a uniform film thickness and a highly accurate coating film 40, the target film thickness is obtained. A cured layer 16 having a uniform film thickness can be produced.
　製造装置１０においては、基本的に、『Ｌ１≧ｄ１＋ｄｃ＋ｄ２』を満たせば良いが、距離Ｌ１は、『ｄ１＋ｄｃ＋ｄ２＋５ｃｍ』未満であるのが好ましい。すなわち、『Ｌ１＜ｄ１＋ｄｃ＋ｄ２＋５ｃｍ』であるのが好ましい。
　さらに、距離Ｌ１は、『ｄ１＋ｄｃ＋ｄ２』に近い方が好ましく、『Ｌ１＝ｄ１＋ｄｃ＋ｄ２』であるのが最も好ましい。 In the manufacturing apparatus 10, basically, “L1 ≧ d1 + dc + d2” may be satisfied, but the distance L1 is preferably less than “d1 + dc + d2 + 5 cm”. That is, it is preferable that “L1 <d1 + dc + d2 + 5 cm”.
Further, the distance L1 is preferably closer to “d1 + dc + d2”, and most preferably “L1 = d1 + dc + d2”.
　第２フィルム１４を適正に搬送するためには、第２フィルム１４に、ある程度の張力を掛ける必要がある。
　ここで、製造装置１０において、貼合ローラ３２とラミネート位置Ｐとの間では、第２フィルム１４は、何にも支持されていない状態で、宙に浮いている。そのため、この宙に浮いている領域では、第２フィルム１４に掛かる張力に起因して、第２フィルム１４の幅方向に波状の変形が生じる。幅方向とは、言い換えれば搬送方向と直交する方向である。
　製造装置１０では、塗膜４０に影響を与えることなく、塗膜４０に第２フィルム１４をラミネートできるが、このような第２フィルム１４の波状の変形は、塗膜４０に膜厚ムラを生じさせる原因とも成り得る。
　これに対して、『Ｌ１＜ｄ１＋ｄｃ＋ｄ２＋５ｃｍ』を満たすことにより、この第２フィルム１４の波状の変形を小さくして、第２フィルム１４の変形に起因する塗膜４０の膜厚ムラを防止できる。 In order to transport the second film 14 properly, it is necessary to apply a certain amount of tension to the second film 14.
Here, in the manufacturing apparatus 10, between the bonding roller 32 and the lamination position P, the 2nd film 14 is floating in the air in a state where nothing is supported. Therefore, in this floating region, a wave-like deformation occurs in the width direction of the second film 14 due to the tension applied to the second film 14. In other words, the width direction is a direction orthogonal to the transport direction.
In the manufacturing apparatus 10, the second film 14 can be laminated on the coating film 40 without affecting the coating film 40, but such wavy deformation of the second film 14 causes film thickness unevenness in the coating film 40. It can also be a cause of
On the other hand, by satisfying “L1 <d1 + dc + d2 + 5 cm”, the wavy deformation of the second film 14 can be reduced, and the film thickness unevenness of the coating film 40 due to the deformation of the second film 14 can be prevented.
　本発明において、第２フィルム１４に掛かる張力は、１００Ｎ／ｍ以下であるのが好ましく、５０Ｎ／ｍ以下であるのがより好ましい。
　第２フィルム１４を適正に搬送するためには、第２フィルム１４に、ある程度の張力を掛ける必要がある。従って、この張力に起因して、第２フィルム１４が塗膜４０を押圧して、塗膜４０の膜厚を変動してしまう可能性がある。
　これに対し、第２フィルム１４に掛かる張力を１００Ｎ／ｍ以下とすることにより、第２フィルム１４に掛かる張力が、塗膜４０の膜厚に影響を与えることを防止でき、より硬化層１６の厚さムラが少ない積層フィルムを得ることができる。 In the present invention, the tension applied to the second film 14 is preferably 100 N / m or less, and more preferably 50 N / m or less.
In order to transport the second film 14 properly, it is necessary to apply a certain amount of tension to the second film 14. Therefore, due to this tension, the second film 14 may press the coating film 40 and change the film thickness of the coating film 40.
On the other hand, by setting the tension applied to the second film 14 to 100 N / m or less, the tension applied to the second film 14 can be prevented from affecting the film thickness of the coating film 40, and more of the cured layer 16. A laminated film with little thickness unevenness can be obtained.
　また、本発明において、第１フィルム１２に掛かる張力をＴ１、第１フィルムの搬送方向のヤング率をＥ１、第１フィルム１２の厚さをｄ１とし、他方、第２フィルム１４に掛かる張力をＴ２、第２フィルム１４の搬送方向のヤング率をＥ２、第２フィルム１４の厚さをｄ２とした際に、下記の式
０．０５＜［Ｔ２／（Ｅ２×ｄ２）］／［Ｔ１／（Ｅ１×ｄ１）］＜２０
を満たすのが好ましく、さらに、下記式
０．１＜［Ｔ２／（Ｅ２×ｄ２）］／［Ｔ１／（Ｅ１×ｄ１）］＜１０
を満たすのがより好ましい。 In the present invention, the tension applied to the first film 12 is T1, the Young's modulus in the transport direction of the first film is E1, the thickness of the first film 12 is d1, and the tension applied to the second film 14 is T2. When the Young's modulus in the transport direction of the second film 14 is E2, and the thickness of the second film 14 is d2, the following formula 0.05 <[T2 / (E2 × d2)] / [T1 / (E1) Xd1)] <20
Preferably, the following formula 0.1 <[T2 / (E2 × d2)] / [T1 / (E1 × d1)] <10
It is more preferable to satisfy.
　本発明においては、第１フィルム１２をバックアップローラ２８に巻き掛けた状態で、塗膜４０を硬化して硬化層１６とする。そのため、積層フィルム２０は第１フィルム１２を内側にしてカールした状態に成り易い。このカールは、第１フィルム１２や第２フィルム１４に掛かる張力等を調節することで、防止することもできるが、調節が上手く行かない場合には、積層フィルム２０が、逆に第２フィルム１４を内側にしてカールしてしまう場合もある。
　これに対して、
０．０５＜［Ｔ２／（Ｅ２×ｄ２）］／［Ｔ１／（Ｅ１×ｄ１）］＜２０
を満たすことにより、第１フィルム１２を内側にしたカール、および、第２フィルム１４を内側にしたカールを大幅に軽減した積層フィルム２０を製造できる。特に、
　　０．１＜［Ｔ２／（Ｅ２×ｄ２）］／［Ｔ１／（Ｅ１×ｄ１）］＜１０
を満たすことにより、より大幅にカールを軽減した、高品位な積層フィルム２０を製造できる。 In the present invention, in the state where the first film 12 is wound around the backup roller 28, the coating film 40 is cured to form the cured layer 16. Therefore, the laminated film 20 tends to be curled with the first film 12 inside. This curl can also be prevented by adjusting the tension applied to the first film 12 and the second film 14, but if the adjustment is not successful, the laminated film 20 is conversely changed to the second film 14. May curl with the inside.
On the contrary,
0.05 <[T2 / (E2 × d2)] / [T1 / (E1 × d1)] <20
By satisfying the above, it is possible to manufacture the laminated film 20 in which the curl with the first film 12 on the inside and the curl with the second film 14 on the inside are greatly reduced. In particular,
0.1 <[T2 / (E2 × d2)] / [T1 / (E1 × d1)] <10
By satisfying the above, it is possible to manufacture a high-quality laminated film 20 with much less curling.
　バックアップローラ２８および貼合ローラ３２の回転精度は高い方が好ましいが、ラジアル振れで０．０５ｍｍ以下が好ましく、０．０１ｍｍ以下であるのがより好ましい。
　バックアップローラ２８および貼合ローラ３２の回転精度を、上記範囲とすることにより、塗膜４０の膜厚分布を、より小さくできる。 Although it is preferable that the rotation accuracy of the backup roller 28 and the bonding roller 32 is high, the radial runout is preferably 0.05 mm or less, and more preferably 0.01 mm or less.
By setting the rotation accuracy of the backup roller 28 and the bonding roller 32 within the above range, the film thickness distribution of the coating film 40 can be further reduced.
　貼合ローラ３２の下流には、バックアップローラ２８に対面して、硬化装置３４が配置される。
　塗膜４０に第２フィルム１４をラミネートした、第１フィルム１２、塗膜４０および第２フィルム１４の積層体は、バックアップローラに巻き掛けられたまま、硬化工程を行う硬化装置３４に搬送される。硬化装置３４は、第１フィルム１２と第２フィルム１４とで挟持された塗膜４０に活性線Ａを照射することにより、塗膜４０を硬化して硬化層１６とし、積層フィルム２０とする。 A curing device 34 is disposed downstream of the bonding roller 32 so as to face the backup roller 28.
The laminate of the first film 12, the coating film 40, and the second film 14 obtained by laminating the second film 14 on the coating film 40 is conveyed to the curing device 34 that performs the curing process while being wound around the backup roller. . The curing device 34 irradiates the coating film 40 sandwiched between the first film 12 and the second film 14 with the active ray A, thereby curing the coating film 40 to form the cured layer 16 and the laminated film 20.
　活性線Ａは、前述のように紫外線、電子線、放射線（α線、β線、γ線等）などの電磁波である。
　硬化装置３４は、塗膜４０を硬化可能な活性線Ａを照射する公知の光源を用いるものが、各種、利用可能である。図示例においては、一例として、硬化装置３４は紫外線を照射する光源を用いている。紫外線を照射する光源は、公知の光源が各種、利用可能である。一例として、ＬＥＤ（Light Emitting Diode）、レーザ光源、低圧水銀灯、中圧水銀灯、高圧水銀灯、超高圧水銀灯、カーボンアーク灯、メタルハライドランプ、キセノンランプ等が例示される。 The active rays A are electromagnetic waves such as ultraviolet rays, electron beams, and radiation (α rays, β rays, γ rays, etc.) as described above.
As the curing device 34, various types of devices that use a known light source that irradiates the active ray A that can cure the coating film 40 can be used. In the illustrated example, as an example, the curing device 34 uses a light source that emits ultraviolet rays. Various known light sources can be used as the light source for irradiating ultraviolet rays. As an example, LED (Light Emitting Diode), laser light source, low pressure mercury lamp, medium pressure mercury lamp, high pressure mercury lamp, super high pressure mercury lamp, carbon arc lamp, metal halide lamp, xenon lamp and the like are exemplified.
　ここで、本発明においては、活性線Ａは、塗膜４０を硬化可能な波長領域に強度分布のピークを有し、かつ、波長に対する強度分布（ピーク）の半値幅が１００ｎｍ以下の電磁波が好ましく、半値幅が５０ｎｍ以下の電磁波がより好ましい。
　すなわち、硬化装置３４は、塗膜４０を硬化可能な波長領域に強度分布のピークを有し、かつ、波長に対する強度分布（ピーク）の半値幅が１００ｎｍ以下の活性線Ａを照射できる、ＬＥＤやレーザ光源等の光源を用いるのが好ましい。 Here, in the present invention, the active ray A is preferably an electromagnetic wave having an intensity distribution peak in a wavelength region where the coating film 40 can be cured, and an intensity distribution (peak) with respect to the wavelength having a half width of 100 nm or less. An electromagnetic wave having a half width of 50 nm or less is more preferable.
That is, the curing device 34 has an intensity distribution peak in a wavelength region where the coating film 40 can be cured, and can emit an active ray A having a half value width of the intensity distribution (peak) with respect to the wavelength of 100 nm or less. It is preferable to use a light source such as a laser light source.
　本発明においては、第１フィルム１２と第２フィルム１４とに挟持された塗膜４０に活性線Ａを照射することで、塗膜４０を硬化する。ここで、活性線Ａは、第１フィルム１２および第２フィルム１４にも吸収されるので、これにより第１フィルム１２および第２フィルム１４が加熱されて、変形する可能性がある。塗膜４０の硬化時に第１フィルム１２や第２フィルム１４が変形すると、この変形に起因して、硬化層１６の厚さが変動し、硬化層１６に厚さムラが生じてしまう。
　これに対し、前述のような半値幅が１００ｎｍ以下の電磁波を用いることにより、塗膜４０の硬化に寄与しない不要な成分の電磁波によって第１フィルム１２および第２フィルム１４が加熱されることを防止できる。その結果、加熱による第１フィルム１２および第２フィルム１４の変形に起因する硬化層１６の膜厚のムラを防止できる。 In the present invention, the coating film 40 is cured by irradiating the coating film 40 sandwiched between the first film 12 and the second film 14 with the active ray A. Here, since the actinic radiation A is also absorbed by the first film 12 and the second film 14, the first film 12 and the second film 14 are thereby heated and may be deformed. If the first film 12 or the second film 14 is deformed when the coating film 40 is cured, the thickness of the cured layer 16 varies due to the deformation, and thickness unevenness occurs in the cured layer 16.
In contrast, by using an electromagnetic wave having a half width of 100 nm or less as described above, the first film 12 and the second film 14 are prevented from being heated by an electromagnetic wave of an unnecessary component that does not contribute to the curing of the coating film 40. it can. As a result, it is possible to prevent unevenness in the thickness of the cured layer 16 due to the deformation of the first film 12 and the second film 14 due to heating.
　硬化装置３４が照射する活性線Ａの照射量は、第１フィルム１２の搬送速度、塗膜４０の膜厚等に応じて、塗膜４０を確実に硬化できる照射量を、適宜、設定すればよい。
　本発明者らの検討によれば、硬化装置３４が照射する活性線Ａの照射量は、１００～１００００ｍＪ／ｃｍ2が好ましく、１０００～４０００ｍＪ／ｃｍ2がより好ましい。
　活性線Ａの照射量を１００ｍＪ／ｃｍ2以上とすることにより、安定して適正な塗膜４０の硬化を行うことができる等の点で好ましい。
　また、活性線Ａの照射量を１００００ｍＪ／ｃｍ2以下とすることにより、余分な活性線Ａによる第１フィルム１２および第２フィルム１４の加熱を防止できる等の点で好ましい。 If the irradiation amount of the actinic radiation A irradiated by the curing device 34 is set appropriately according to the transport speed of the first film 12, the film thickness of the coating film 40, etc., the irradiation amount that can reliably cure the coating film 40 is set. Good.
According to the studies of the present inventors, the irradiation amount of the active wiring A curing device 34 is irradiated is preferably 100 ~ 10000mJ / cm 2, more preferably 1000 ~ 4000mJ / cm 2.
By setting the irradiation amount of the actinic ray A to 100 mJ / cm 2 or more, it is preferable in that the appropriate coating film 40 can be stably cured.
In addition, it is preferable to set the irradiation amount of the active ray A to 10000 mJ / cm 2 or less in that the heating of the first film 12 and the second film 14 due to the excess active ray A can be prevented.
　ラミネート位置Ｐから硬化装置３４による活性線Ａの照射位置までの距離Ｌ２は、バックアップローラ２８のサイズ、塗膜４０の膜厚、硬化装置３４による活性線Ａの照射量等に応じて、適宜、設定すればよい。
　ここで、ラミネート位置Ｐから硬化装置３４による活性線Ａの照射位置までの距離Ｌ２は、３０ｍｍ以上が好ましく、５０ｍｍ以上がより好ましい。
　これにより、第２フィルム１４をラミネートした後の塗膜４０のレベリング効果を十分に得て、硬化層１６の膜厚分布を良好にできる等の点で好ましい。 The distance L2 from the lamination position P to the irradiation position of the active ray A by the curing device 34 is appropriately determined according to the size of the backup roller 28, the film thickness of the coating film 40, the irradiation amount of the active ray A by the curing device 34, etc. You only have to set it.
Here, the distance L2 from the lamination position P to the irradiation position of the active ray A by the curing device 34 is preferably 30 mm or more, and more preferably 50 mm or more.
This is preferable in that the leveling effect of the coating film 40 after the second film 14 is laminated can be sufficiently obtained, and the film thickness distribution of the cured layer 16 can be improved.
　また、本発明においては、塗膜４０に活性線Ａを照射する前の第１フィルム１２および第２フィルム１４の温度と、塗膜４０に活性線Ａを照射した後の第１フィルム１２および第２フィルム１４の温度との差が、２５℃以下であるのが好ましい。
　この温度差を２５℃以下とすることにより、第１フィルム１２および第２フィルム１４にシワが発生することを防止できる。 In the present invention, the temperature of the first film 12 and the second film 14 before the coating film 40 is irradiated with the active ray A, and the first film 12 and the second film 14 after the coating film 40 is irradiated with the active ray A are used. The difference from the temperature of the two films 14 is preferably 25 ° C. or less.
By setting this temperature difference to 25 ° C. or less, wrinkles can be prevented from occurring in the first film 12 and the second film 14.
　硬化装置３４の下流には、剥離ローラ３６が配置される。
　塗膜４０の硬化による硬化層１６を形成によって製造された積層フィルム２０は、次いで、剥離ローラ３６によってバックアップローラ２８から剥離され、所定の搬送経路を搬送されて、図示しない巻取り軸に巻き取られて、積層フィルム２０を巻回したロールとされる。 A peeling roller 36 is disposed downstream of the curing device 34.
The laminated film 20 produced by forming the cured layer 16 by curing the coating film 40 is then peeled off from the backup roller 28 by the peeling roller 36 and conveyed along a predetermined conveyance path to be wound around a winding shaft (not shown). And a roll in which the laminated film 20 is wound.
　以下、図１および図２に示す製造装置１０の作用を説明することにより、本発明の積層フィルムの製造方法および製造について、より詳細に説明する。
　まず、第１フィルムロール１２Ｒから第１フィルム１２を引き出し、バックアップローラ２８に巻き掛け、剥離ローラ３６を経て巻取り軸に到る所定の搬送経路に通す。また、第２フィルムロール１４Ｒから第２フィルム１４を引き出し、貼合ローラ３２を経て、バックアップローラ２８に巻き掛け、剥離ローラ３６を経て巻取り軸に到る所定の搬送経路に通す。
　さらに、塗布装置３０に、塗膜４０すなわち硬化層１６となる塗布液を充填する。 Hereinafter, the production method and production of the laminated film of the present invention will be described in more detail by explaining the operation of the production apparatus 10 shown in FIGS. 1 and 2.
First, the first film 12 is pulled out from the first film roll 12R, wound around the backup roller 28, and passed through a predetermined conveyance path that reaches the take-up shaft through the peeling roller 36. Further, the second film 14 is pulled out from the second film roll 14R, wound around the backup roller 28 via the laminating roller 32, and passed through a predetermined transport path reaching the winding shaft via the peeling roller 36.
Further, the coating device 30 is filled with a coating solution that becomes the coating film 40, that is, the cured layer 16.
　次いで、第１フィルム１２および第２フィルム１４の搬送速度が所定速度となるように、第１フィルムロール１２Ｒ、第２フィルムロール１４Ｒ、バックアップローラ２８、貼合ローラ３２、剥離ローラ３６、および、図示しない巻取り軸を同期して回転して、第１フィルム１２および第２フィルム１４の搬送を開始する。
　その後、塗布装置３０および硬化装置３４の駆動を開始する。 Next, the first film roll 12R, the second film roll 14R, the backup roller 28, the laminating roller 32, the peeling roller 36, and the illustration so that the conveyance speed of the first film 12 and the second film 14 becomes a predetermined speed. The take-up shaft that is not rotated is rotated synchronously, and the conveyance of the first film 12 and the second film 14 is started.
Thereafter, driving of the coating device 30 and the curing device 34 is started.
　第１フィルムロール１２Ｒから送り出された第１フィルム１２は、バックアップローラ２８に巻き掛けられた状態で長手方向に搬送されつつ、塗布装置３０によって塗料を塗布されて、表面に塗膜４０が形成される。
　第１フィルム１２の表面に塗膜４０を形成された積層体は、次いで、ラミネート位置Ｐまで搬送され、バックアップローラ２８に巻き掛けられた状態で長手方向に搬送されつつ、ラミネート位置Ｐにおいて、貼合ローラ３２によって、第２フィルムロール１４Ｒから送り出された第２フィルム１４が、塗膜４０にラミネートされる。
　第１フィルム１２と第２フィルム１４とで塗膜４０を挟持した積層体は、次いで、硬化装置３４まで搬送され、バックアップローラ２８に巻き掛けられた状態で長手方向に搬送されつつ、硬化装置３４によって活性線Ａを照射され、第１フィルム１２と第２フィルム１４とに挟持された塗膜４０が硬化されて、硬化層１６が形成される。これにより、積層フィルム２０が作製される。
　硬化層１６の形成によって作製された積層フィルム２０は、剥離ローラ３６によってバックアップローラ２８から剥離され、所定の搬送経路を搬送されて、巻取り軸によって巻き取られる。 The first film 12 fed out from the first film roll 12R is coated with a coating material by the coating device 30 while being conveyed in the longitudinal direction while being wound around the backup roller 28, and the coating film 40 is formed on the surface. The
The laminate having the coating film 40 formed on the surface of the first film 12 is then transported to the laminating position P and is transported in the longitudinal direction while being wound around the backup roller 28, while being pasted at the laminating position P. The second film 14 delivered from the second film roll 14 </ b> R is laminated to the coating film 40 by the combined roller 32.
The laminate in which the coating film 40 is sandwiched between the first film 12 and the second film 14 is then conveyed to the curing device 34 and is conveyed in the longitudinal direction while being wound around the backup roller 28, while the curing device 34. As a result, the active ray A is irradiated, the coating film 40 sandwiched between the first film 12 and the second film 14 is cured, and the cured layer 16 is formed. Thereby, the laminated film 20 is produced.
The laminated film 20 produced by forming the hardened layer 16 is peeled off from the backup roller 28 by the peeling roller 36, transported along a predetermined transport path, and taken up by a winding shaft.
　以上の説明のように、本発明では、硬化層１６を第１フィルム１２および第２フィルム１４で挟持した積層フィルム２０の製造において、第１フィルム１２への塗布液の塗布による塗膜４０の形成、塗膜４０への第２フィルム１４のラミネート、および、第１フィルム１２と第２フィルム１４とに挟持された塗膜４０の硬化を、全て、第１フィルム１２をバックアップローラ２８に巻き掛けた状態で行う。
　これにより、塗膜４０の膜厚にムラが生じることを防止して、硬化層１６の膜厚の均一性が高い、高品位な積層フィルム２０を製造できる。 As described above, in the present invention, in the production of the laminated film 20 in which the cured layer 16 is sandwiched between the first film 12 and the second film 14, the coating film 40 is formed by applying the coating liquid to the first film 12. The first film 12 was wound around the backup roller 28 for the lamination of the second film 14 onto the coating film 40 and the curing of the coating film 40 sandwiched between the first film 12 and the second film 14. Do in state.
Thereby, it can prevent that the film thickness of the coating film 40 produces a nonuniformity, and can manufacture the high quality laminated | multilayer film 20 with the high uniformity of the film thickness of the hardened layer 16. FIG.
　特許文献１および特許文献２に示されるように、従来の積層フィルムの製造では、第１フィルムへの塗布液の塗布は、ローラ対等によって第１フィルムを挟持搬送しつつ行う。周知のように、第１フィルムの搬送を適正に行うためには、第１フィルムに、ある程度の張力を掛ける必要がある。
　ここで、塗布液を塗布によって塗膜を形成された第１フィルムは、何にも支持されていない状態で、宙に浮いている状態となる。そのため、この宙に浮いている領域では、第１フィルム１２に掛かる張力によって、第１フィルム１２の幅方向に波状の変形が生じる。
　第１フィルム１２が変形すると、変形に応じて、塗膜を形成する塗布液が流動する。その結果、この塗布液の流動によって、塗膜の膜厚が変動して、塗膜の膜厚にムラが生じる。膜厚にムラを有する塗膜を硬化すると、当然、形成される硬化層の膜厚にも、ムラが生じてしまう。
　そのため、従来の積層フィルムの製造では、硬化層の膜厚の均一性が高い積層フィルムを製造することは、困難であった。 As shown in Patent Document 1 and Patent Document 2, in the production of a conventional laminated film, the coating liquid is applied to the first film while the first film is nipped and conveyed by a roller pair or the like. As is well known, in order to properly transport the first film, it is necessary to apply a certain amount of tension to the first film.
Here, the 1st film in which the coating film was formed by apply | coating a coating liquid will be in the state which is floating in the air in the state which is not supported on anything. Therefore, in this floating region, a wave-like deformation occurs in the width direction of the first film 12 due to the tension applied to the first film 12.
When the first film 12 is deformed, the coating liquid for forming the coating film flows according to the deformation. As a result, the film thickness of the coating film fluctuates due to the flow of the coating solution, and unevenness occurs in the film thickness of the coating film. When a coating film having unevenness in film thickness is cured, naturally, unevenness occurs in the film thickness of the formed cured layer.
For this reason, it has been difficult to produce a laminated film with high uniformity of the thickness of the cured layer in the production of a conventional laminated film.
　これに対し、本発明においては、前述のように、第１フィルム１２への塗膜４０の形成、塗膜４０への第２フィルム１４のラミネート、および、第１フィルム１２と第２フィルム１４とに挟持された塗膜４０の硬化を、全て、第１フィルム１２をバックアップローラ２８に巻き掛けた状態で行う。
　従って、第１フィルム１２は、常にバックアップローラ２８によって支持されており、波状の変形を生じることはない。これにより、第１フィルム１２の変形による塗膜４０の膜厚ムラすなわち硬化層１６の膜厚ムラを防止できる。
　加えて、本発明においては、塗膜４０および第２フィルム１４も、常にバックアップローラ２８によって支持されている。そのため、塗膜４０および第２フィルム１４の変形も防止でき、塗膜４０および第２フィルム１４の変形に起因する、硬化層１６の膜厚ムラも防止できる。
　従って、本発明によれば、硬化層１６の膜厚の均一性が高い、高品位な積層フィルム２０を安定して製造できる。 On the other hand, in the present invention, as described above, the formation of the coating film 40 on the first film 12, the lamination of the second film 14 on the coating film 40, and the first film 12 and the second film 14 Curing of the coating film 40 sandwiched between the two is performed in a state where the first film 12 is wound around the backup roller 28.
Accordingly, the first film 12 is always supported by the backup roller 28 and does not cause a wave-like deformation. Thereby, the film thickness nonuniformity of the coating film 40 by the deformation | transformation of the 1st film 12, ie, the film thickness nonuniformity of the cured layer 16, can be prevented.
In addition, in the present invention, the coating film 40 and the second film 14 are always supported by the backup roller 28. Therefore, deformation of the coating film 40 and the second film 14 can also be prevented, and uneven thickness of the cured layer 16 due to deformation of the coating film 40 and the second film 14 can also be prevented.
Therefore, according to the present invention, it is possible to stably manufacture a high-quality laminated film 20 with high uniformity of the film thickness of the cured layer 16.
　図３に、本発明の製造装置の別の態様の一例を概念的に示す。また、図４に、図３の部分拡大図を示す。
　なお、図３および図４に示す製造装置５０は、貼合ローラ５２とバックアップローラ２８との位置関係が異なる以外は、前述の製造装置１０と同様の構成を有する。従って、同じ部材には同じ符号を付し、以下の説明は、異なる点を主に行う。 In FIG. 3, an example of another aspect of the manufacturing apparatus of this invention is shown notionally. FIG. 4 is a partially enlarged view of FIG.
The manufacturing apparatus 50 shown in FIGS. 3 and 4 has the same configuration as the above-described manufacturing apparatus 10 except that the positional relationship between the bonding roller 52 and the backup roller 28 is different. Accordingly, the same members are denoted by the same reference numerals, and the following description mainly focuses on different points.
　前述の製造装置１０は、バックアップローラ２８と貼合ローラ３２との距離Ｌ１が、第１フィルム１２の厚さｄ１、塗膜４０の厚さｄｃ、および、第２フィルムの厚さｄ２の合計以上である。すなわち、前述のように『Ｌ１≧ｄ１＋ｄｃ＋ｄ２』である。
　これに対し、図３および図４に示す製造装置５０では、バックアップローラ２８と貼合ローラ３２との距離Ｌ１が、第１フィルム１２の厚さｄ１、塗膜４０の厚さｄｃ、および、第２フィルムの厚さｄ２の合計未満である。すなわち、本態様では『Ｌ１＜ｄ１＋ｄｃ＋ｄ２』である。
　言い換えれば、製造装置５０では、貼合ローラ３２に巻き掛かっている状態で第２フィルム１４が塗膜４０に接触しており、すなわち、ラミネート位置Ｐで第２フィルム１４が貼合ローラに巻き掛かっている。 In the manufacturing apparatus 10 described above, the distance L1 between the backup roller 28 and the bonding roller 32 is equal to or greater than the sum of the thickness d1 of the first film 12, the thickness dc of the coating film 40, and the thickness d2 of the second film. It is. That is, as described above, “L1 ≧ d1 + dc + d2”.
On the other hand, in the manufacturing apparatus 50 shown in FIGS. 3 and 4, the distance L1 between the backup roller 28 and the bonding roller 32 is the thickness d1 of the first film 12, the thickness dc of the coating film 40, and the first Less than the sum of the thicknesses d2 of the two films. That is, in this aspect, “L1 <d1 + dc + d2”.
In other words, in the manufacturing apparatus 50, the second film 14 is in contact with the coating film 40 while being wound around the bonding roller 32, that is, the second film 14 is wound around the bonding roller at the lamination position P. ing.
　そのため、図４に概念的に示すように、ラミネート位置Ｐにおいて、塗膜４０を第２フィルム１４によって押圧して、塗膜４０の膜厚を変更できる。すなわち、製造装置５０では、バックアップローラ２８と貼合ローラ３２との距離Ｌ１を調節することによって、塗膜４０の膜厚を調節できる。 Therefore, as conceptually shown in FIG. 4, the film thickness of the coating film 40 can be changed by pressing the coating film 40 with the second film 14 at the lamination position P. That is, in the manufacturing apparatus 50, the film thickness of the coating film 40 can be adjusted by adjusting the distance L1 between the backup roller 28 and the bonding roller 32.
　前述の図１および図２に示す製造装置１０は、塗布装置３０によって、膜厚が均一な、目的とする膜厚の塗膜４０を、必要にして十分な精度で形成できる場合に対応する。
　これに対して、図３および図４に示す製造装置５０は、塗布装置３０による塗布液の塗布の制御を高精度に行わない場合に、好適に対応する。
　前述のように、本発明においては、第１フィルム１２への塗膜４０の形成等を全て、第１フィルム１２をバックアップローラ２８に巻き掛けた状態で行うため、ラミネート位置Ｐにおいて、第１フィルム１２の変形に起因する塗膜４０の膜厚のムラが無い。そのため、第２フィルム１４の押圧による塗膜４０の膜厚調節を、非常に高精度に行うことができる。
　また、製造装置５０においては、塗膜４０に第２フィルム１４をラミネートする際に、塗膜４０と第２フィルム１４との間に空気（気体）が巻き込まれることも防止できる。すなわち、この態様は、装置構成等に応じて、塗膜４０と第２フィルム１４との間への空気の巻き込みが問題になる場合にも、好適に対応できる。 The manufacturing apparatus 10 shown in FIG. 1 and FIG. 2 described above corresponds to the case where the coating apparatus 40 can form the coating film 40 having a uniform film thickness and having a desired film thickness with sufficient accuracy.
On the other hand, the manufacturing apparatus 50 shown in FIG. 3 and FIG. 4 is suitable for a case where the application liquid application control by the application apparatus 30 is not performed with high accuracy.
As described above, in the present invention, the formation of the coating film 40 on the first film 12 is all performed in a state where the first film 12 is wound around the backup roller 28. There is no unevenness in the film thickness of the coating film 40 due to the deformation of 12. Therefore, the film thickness adjustment of the coating film 40 by pressing the second film 14 can be performed with very high accuracy.
Further, in the manufacturing apparatus 50, when the second film 14 is laminated on the coating film 40, it is possible to prevent air (gas) from being caught between the coating film 40 and the second film 14. In other words, this aspect can be suitably handled even when air entrainment between the coating film 40 and the second film 14 becomes a problem, depending on the device configuration and the like.
　本態様の製造装置５０においては、基本的に、塗膜４０の膜厚と目的とする硬化層１６の膜厚とに応じて、『Ｌ１＜ｄ１＋ｄｃ＋ｄ２』満たせばよい。 In the manufacturing apparatus 50 of this embodiment, basically, “L1 <d1 + dc + d2” may be satisfied according to the film thickness of the coating film 40 and the target film thickness of the cured layer 16.
　製造装置５０において、塗膜４０の厚さは、前述の製造装置１０と同様、硬化層１６の膜厚等に応じて、適宜、設定すればよい。好ましい塗膜４０の膜厚も、同様である。
　塗膜４０の厚さの調節量も、硬化層１６の膜厚、塗膜４０の膜厚の精度、厚さを調節する前の塗膜４０の膜厚等に応じて、適宜、設定すればよい。 In the manufacturing apparatus 50, the thickness of the coating film 40 may be appropriately set according to the film thickness of the cured layer 16 and the like, similar to the manufacturing apparatus 10 described above. The film thickness of the preferable coating film 40 is also the same.
If the adjustment amount of the thickness of the coating film 40 is also set appropriately according to the film thickness of the cured layer 16, the accuracy of the film thickness of the coating film 40, the film thickness of the coating film 40 before adjusting the thickness, and the like. Good.
　以上、本発明の積層フィルムの製造方法および積層フィルムの製造装置について詳細に説明したが、本発明は、上記実施例に限定はされず、本発明の要旨を逸脱しない範囲において、各種の改良や変更を行なってもよいのは、もちろんである。 As mentioned above, although the manufacturing method and the manufacturing apparatus of the laminated film of this invention were demonstrated in detail, this invention is not limited to the said Example, In the range which does not deviate from the summary of this invention, various improvement and Of course, changes may be made.
　以下、本発明の具体的実施例を挙げ、本発明を、より詳細に説明する。ただし、本発明はこの実施例に限定されるものでなく、以下の実施例に示す材料、使用量、割合、処理内容、処理手順などは、本発明の趣旨を逸脱しない限り適宜変更することができる。 Hereinafter, specific examples of the present invention will be given and the present invention will be described in more detail. However, the present invention is not limited to this example, and materials, amounts used, ratios, processing contents, processing procedures, and the like shown in the following examples can be changed as appropriate without departing from the spirit of the present invention. it can.
　［実施例１］
　第１フィルム１２および第２フィルム１４として、厚さ１００μｍ、幅１０００ｍｍのＰＥＴフィルム（東洋紡社製、コスモシャインＡ４３００）を用意した。
　また、塗布装置が塗布する塗布液として、以下の塗布液を調製した。
　（塗布液の組成）
　・量子ドット１のトルエン分散液（発光極大：５２０ｎｍ）　１０質量部
　・量子ドット２のトルエン分散液（発光極大：６３０ｎｍ）　１質量部
　・ラウリルメタクリレート　２．４質量部
　・トリメチロールプロパントリアクリレート　０．５４質量部
　・光重合開始剤（イルガキュア８１９、ＢＡＳＦ社製）　０．００９質量部
　量子ドット１、２としては、下記のコア－シェル構造（ＩｎＰ／ＺｎＳ）を有するナノ結晶を用いた。
　・量子ドット１：ＩＮＰ５３０－１０（ＮＮ－ｌａｂｓ社製）
　・量子ドット２：ＩＮＰ６２０－１０（ＮＮ－ｌａｂｓ社製） [Example 1]
As the first film 12 and the second film 14, a PET film having a thickness of 100 μm and a width of 1000 mm (manufactured by Toyobo Co., Ltd., Cosmo Shine A4300) was prepared.
Moreover, the following coating liquid was prepared as a coating liquid which a coating device apply | coats.
(Composition of coating solution)
-Toluene dispersion of quantum dots 1 (luminescence maximum: 520 nm) 10 parts by mass-Toluene dispersion of quantum dots 2 (luminescence maximum: 630 nm) 1 part by weight-Lauryl methacrylate 2.4 parts by weight-Trimethylolpropane triacrylate 0. 54 parts by mass Photopolymerization initiator (Irgacure 819, manufactured by BASF) 0.009 parts by mass As the quantum dots 1 and 2, nanocrystals having the following core-shell structure (InP / ZnS) were used.
・ Quantum dot 1: INP530-10 (manufactured by NN-labs)
Quantum dot 2: INP620-10 (manufactured by NN-labs)
　ＥＭＳ粘度計（京都電子工業社製）によって剪断速度０．１／ｓで粘度を測定したところ、調製した組成物の５０ｍＰａ・ｓであった。 When the viscosity was measured with an EMS viscometer (manufactured by Kyoto Electronics Industry Co., Ltd.) at a shear rate of 0.1 / s, it was 50 mPa · s of the prepared composition.
　このような第１フィルム１２および第２フィルム、ならびに塗布液を用いて、図１に示す製造装置１０によって積層フィルム２０を作製した。
　バックアップローラ２８は、温度調節手段を内蔵する、直径が２００ｍｍのステンレス製であり、表面の温度２５℃に調節した。
　第１フィルム１２の搬送速度は１ｍ／分とし、第１フィルム１２および第２フィルム１４に掛かる張力は、１００Ｎ／ｍとした。
　また、塗膜４０の膜厚は７０μｍとした。従って、本例では、硬化層１６の厚さは、ほぼ７０μｍとなる。
　バックアップローラと貼合ローラとの距離Ｌ１は１０ｍｍとした。
　硬化装置３４は、中心波長が３６５ｎｍで半値幅が１０ｎｍの紫外線を照射するＬＥＤ（センテック社製、ＵＶ－ＬＥＤ２３３Ａ）を光源として用いた。紫外線の照射量は９００ｍＪ／ｃｍ2とした。
　［Ｔ２／（Ｅ２×ｄ２）］／［Ｔ１／（Ｅ１×ｄ１）］は１であった。 Using the first film 12 and the second film, and the coating liquid, a laminated film 20 was produced by the production apparatus 10 shown in FIG.
The backup roller 28 is made of stainless steel having a diameter of 200 mm, which incorporates temperature adjusting means, and the surface temperature was adjusted to 25 ° C.
The conveyance speed of the first film 12 was 1 m / min, and the tension applied to the first film 12 and the second film 14 was 100 N / m.
Moreover, the film thickness of the coating film 40 was 70 micrometers. Therefore, in this example, the thickness of the hardened layer 16 is approximately 70 μm.
The distance L1 between the backup roller and the bonding roller was 10 mm.
As the curing device 34, an LED (UV-LED 233A, manufactured by Sentec Co., Ltd.) that irradiates ultraviolet rays having a center wavelength of 365 nm and a half width of 10 nm was used as a light source. The irradiation amount of ultraviolet rays was set to 900 mJ / cm 2 .
[T2 / (E2 × d2)] / [T1 / (E1 × d1)] was 1.
　［比較例１］
　第２フィルム１４のラミネートおよび塗膜の硬化を、バックアップローラ２８から第１フィルム１２を外した後、別途、バックアップローラ２８の下流に配置したローラ対によって挟持搬送しつつ行った以外は、実施例１と同様にして積層フィルムを作製した。 [Comparative Example 1]
Example 2 except that the lamination of the second film 14 and the curing of the coating film were performed while the first film 12 was removed from the backup roller 28 and then separately conveyed by a pair of rollers arranged downstream of the backup roller 28. A laminated film was produced in the same manner as in 1.
　［実施例２～３］
　硬化装置３４の光源として、ＬＥＤに変えて、中心波長が３６５ｎｍの紫外線を照射するメタルハライドランプ（アイグラフィックス社製、Ｍ３０－Ｌ５１Ｘ）を用いた。この光源は、主な発光波長領域が２００～４５０ｎｍで、発光の波長幅が広いため、半値幅は１００ｎｍを超えている。
　＜実施例２＞
　上記光源を用い、紫外線の照射量を９００ｍＪ／ｃｍ2とし、バックアップローラ２８の表面温度を５５℃にした以外は、実施例１と同様にして積層フィルム２０を作製した。
　＜実施例３＞
　上記光源を用い、紫外線の照射量を５０ｍＪ／ｃｍ2とし、バックアップローラ２８の表面温度を２５℃にした以外は、実施例１と同様にして積層フィルム２０を作製した。 [Examples 2 to 3]
As the light source of the curing device 34, a metal halide lamp (M30-L51X, manufactured by Eye Graphics Co., Ltd.) that irradiates ultraviolet rays having a center wavelength of 365 nm was used instead of the LED. This light source has a main light emission wavelength region of 200 to 450 nm and a wide light emission wavelength width, so that the half-value width exceeds 100 nm.
<Example 2>
A laminated film 20 was produced in the same manner as in Example 1 except that the above light source was used, the irradiation amount of ultraviolet rays was 900 mJ / cm 2, and the surface temperature of the backup roller 28 was 55 ° C.
<Example 3>
A laminated film 20 was produced in the same manner as in Example 1 except that the light source was used, the irradiation amount of ultraviolet rays was 50 mJ / cm 2, and the surface temperature of the backup roller 28 was 25 ° C.
　［実施例４～８］
　＜実施例４＞
　第２フィルム１４の張力を１０Ｎ／ｍにした以外は、実施例１と同様に積層フィルム２０を作製した。
　［Ｔ２／（Ｅ２×ｄ２）］／［Ｔ１／（Ｅ１×ｄ１）］は０．１であった。
　＜実施例５＞
　第２フィルム１４の張力を２００Ｎ／ｍにした以外は、実施例１と同様に積層フィルム２０を作製した。
　［Ｔ２／（Ｅ２×ｄ２）］／［Ｔ１／（Ｅ１×ｄ１）］は２であった。
　＜実施例６＞
　第２フィルム１４の張力を１０００Ｎ／ｍにした以外は、実施例１と同様に積層フィルム２０を作製した。
　［Ｔ２／（Ｅ２×ｄ２）］／［Ｔ１／（Ｅ１×ｄ１）］は１０であった。
　＜実施例７＞
　第２フィルム１４の張力を５Ｎ／ｍにした以外は、実施例１と同様に積層フィルム２０を作製した。
　［Ｔ２／（Ｅ２×ｄ２）］／［Ｔ１／（Ｅ１×ｄ１）］は０．０５であった。
　＜実施例８＞
　第１フィルム１２の張力を５０Ｎ／ｍとし、第２フィルム１４の張力を１０００Ｎ／ｍにした以外は、実施例１と同様に積層フィルム２０を作製した。
　［Ｔ２／（Ｅ２×ｄ２）］／［Ｔ１／（Ｅ１×ｄ１）］は２０であった。 [Examples 4 to 8]
<Example 4>
A laminated film 20 was produced in the same manner as in Example 1 except that the tension of the second film 14 was 10 N / m.
[T2 / (E2 × d2)] / [T1 / (E1 × d1)] was 0.1.
<Example 5>
A laminated film 20 was produced in the same manner as in Example 1 except that the tension of the second film 14 was 200 N / m.
[T2 / (E2 × d2)] / [T1 / (E1 × d1)] was 2.
<Example 6>
A laminated film 20 was produced in the same manner as in Example 1 except that the tension of the second film 14 was 1000 N / m.
[T2 / (E2 × d2)] / [T1 / (E1 × d1)] was 10.
<Example 7>
A laminated film 20 was produced in the same manner as in Example 1 except that the tension of the second film 14 was changed to 5 N / m.
[T2 / (E2 × d2)] / [T1 / (E1 × d1)] was 0.05.
<Example 8>
A laminated film 20 was produced in the same manner as in Example 1 except that the tension of the first film 12 was 50 N / m and the tension of the second film 14 was 1000 N / m.
[T2 / (E2 × d2)] / [T1 / (E1 × d1)] was 20.
　［実施例９］
　バックアップローラと貼合ローラとの距離Ｌ１が２６０μｍである、図３および図４に示す製造装置５０を用いた以外は、実施例１と同様に積層フィルム２０を作製した。
　従って、本例においては、硬化層１６の厚さは６０μｍとなる。 [Example 9]
A laminated film 20 was produced in the same manner as in Example 1 except that the manufacturing apparatus 50 shown in FIGS. 3 and 4 in which the distance L1 between the backup roller and the bonding roller was 260 μm was used.
Therefore, in this example, the thickness of the hardened layer 16 is 60 μm.
　［比較例２］
　第１フィルム１２への塗布液の塗布を、第１フィルム１２をバックアップローラに巻き掛ける前に行った以外は、実施例１と同様に積層フィルムを作製した。 [Comparative Example 2]
A laminated film was produced in the same manner as in Example 1 except that the coating liquid was applied to the first film 12 before the first film 12 was wound around the backup roller.
　［フィルムのカール］
　作製した積層フィルムについて、カールの半径を測定することによって、フィルムのカールを評価した。
　カールの半径が５００ｍｍ超である場合をＡ；
　カールの半径が５０ｍｍ超５００ｍｍ以下である場合をＢ；
　カールの半径が５０ｍｍ以下である場合をＣ；　と評価した。 [Film curl]
About the produced laminated | multilayer film, the curl of the film was evaluated by measuring the radius of curl.
A when the radius of curl is greater than 500 mm;
B when the curl radius is greater than 50 mm and less than or equal to 500 mm;
The case where the radius of curl was 50 mm or less was evaluated as C;
　［厚さムラ］
　作製した積層フィルムの膜厚を接触式の厚さ計測装置（山文電気社製、ＴＯＦ５Ｒ）によって測定し、積層フィルムの膜厚の測定結果から第１フィルム１２および第２フィルム１４の膜厚を差し引くことにより、硬化層１６の膜厚を測定した。
　この硬化層１６の膜厚測定をフィルムの搬送方向、および、フィルムの搬送方向と直交する方向に、１ｍｍ間隔、１０００点で行い、平均膜厚に対する最小膜厚および最大膜厚から、厚さムラを算出した。なお、フィルムの搬送方向と直交する方向とは、すなわち、フィルムの幅方向である。
　厚さムラが±２％未満のものをＡ；
　厚さムラが±２％以上±３％未満のものをＢ；
　厚さムラが±３％以上のものをＣ；　と評価した。
　結果を下記の表に示す。 [Thickness unevenness]
The film thickness of the produced laminated film is measured with a contact-type thickness measuring device (manufactured by Yamabun Electric Co., Ltd., TOF5R), and the film thicknesses of the first film 12 and the second film 14 are determined from the measurement results of the film thickness of the laminated film. By subtracting, the film thickness of the cured layer 16 was measured.
The film thickness of the cured layer 16 is measured at 1000 points at 1 mm intervals in the film transport direction and in the direction orthogonal to the film transport direction, and the thickness unevenness is determined from the minimum film thickness and the maximum film thickness with respect to the average film thickness. Was calculated. In addition, the direction orthogonal to the conveyance direction of a film is the width direction of a film.
A with thickness unevenness less than ± 2%;
B with thickness unevenness of ± 2% or more and less than ± 3%
A film having a thickness unevenness of ± 3% or more was evaluated as C;
The results are shown in the table below.
Figure JPOXMLDOC01-appb-T000001
Figure JPOXMLDOC01-appb-T000001
　上記表に示されるように、バックアップローラ２８から外れた状態で第２フィルム１４のラミネートおよび塗膜の硬化を行う比較例１や、バックアップローラ２８に巻き掛ける前に塗膜の形成を行う比較例２では、硬化層の厚さムラが３％を超えている。
　これに対し、塗膜の形成、第２フィルム１４のラミネートおよび塗膜の硬化を、全て、第１フィルム１２をバックアップローラ２８に巻き掛けて行う本発明によれば、硬化層１６の厚さムラを抑えることができる。特に、実施例１、３、４、７および９に示されるように、第２フィルムに掛かる張力が１００Ｎ／ｍ以下、塗膜４０を硬化する活性線の半値幅が１００ｎｍ以下、バックアップローラ２８の表面温度が５５℃以下という条件を全て満たすことにより、硬化層１６の厚さムラが±２％未満と、非常に硬化層１６の膜厚ムラが小さい積層フィルムが得られる。なお、厚さムラの評価が『Ｂ』であっても、厚さムラは±３％未満であるので、通常であれば、実用上、問題は無い。
　また、実施例１～６および９に示されるように、０．０５＜［Ｔ２／（Ｅ２×ｄ２）］／［Ｔ１／（Ｅ１×ｄ１）］＜２０を満たすことにより、積層フィルムのカールを大幅に軽減できる。特に、実施例１～３、５および９に示されるように、０．１＜［Ｔ２／（Ｅ２×ｄ２）］／［Ｔ１／（Ｅ１×ｄ１）］＜１０を満たすことにより、カールの半径が５００ｍｍを超える、非常にカールの小さい積層フィルムを得ることができる。なお、カールの評価が『Ｂ』であっても、カールの半径は５０ｍｍ超であるので、通常であれば、実用上、問題は無い。また、カールの評価が『Ｃ』であっても、公知の方法でカールは矯正できるので、実用上、問題はない。
　以上の結果より、本発明の効果は明らかである。 As shown in the above table, Comparative Example 1 in which the second film 14 is laminated and the coating film is cured in a state of being detached from the backup roller 28, and Comparative Example in which the coating film is formed before being wound around the backup roller 28. In 2, the thickness unevenness of the hardened layer exceeds 3%.
On the other hand, according to the present invention in which the formation of the coating film, the lamination of the second film 14 and the curing of the coating film are all performed by winding the first film 12 around the backup roller 28, the thickness unevenness of the cured layer 16 is increased. Can be suppressed. In particular, as shown in Examples 1, 3, 4, 7, and 9, the tension applied to the second film is 100 N / m or less, the half width of the active line for curing the coating film 40 is 100 nm or less, the backup roller 28 By satisfying all the conditions that the surface temperature is 55 ° C. or less, a laminated film having a thickness unevenness of the cured layer 16 of less than ± 2% and a very small thickness unevenness of the cured layer 16 can be obtained. Even if the evaluation of the thickness unevenness is “B”, the thickness unevenness is less than ± 3%, so that there is no problem in practical use if it is normal.
Further, as shown in Examples 1 to 6 and 9, when 0.05 <[T2 / (E2 × d2)] / [T1 / (E1 × d1)] <20 is satisfied, curling of the laminated film is achieved. Can be greatly reduced. In particular, as shown in Examples 1 to 3, 5 and 9, the radius of the curl is satisfied by satisfying 0.1 <[T2 / (E2 × d2)] / [T1 / (E1 × d1)] <10. A laminated film with a very small curl can be obtained. Note that even if the curl evaluation is “B”, the curl radius is more than 50 mm. Even if the curl evaluation is “C”, there is no practical problem because the curl can be corrected by a known method.
From the above results, the effects of the present invention are clear.
　波長変換フィルム等の各種の積層フィルムの製造に好適に利用可能である。 It can be suitably used for manufacturing various laminated films such as wavelength conversion films.
　１０，５０　（積層フィルムの）製造装置
　１２　第１フィルム（第１のフィルム）
　１４　第２フィルム（第２のフィルム）
　１６　硬化層
　２０　積層フィルム
　２４　第１供給部
　２６　第２供給部
　２８　バックアップローラ
　３０　塗布装置
　３２，５２　貼合ローラ
　３４　硬化装置
　３６　剥離ローラ
　４０　塗膜 10, 50 (laminated film) production device 12 first film (first film)
14 Second film (second film)
DESCRIPTION OF SYMBOLS 16 Hardened layer 20 Laminated | multilayer film 24 1st supply part 26 2nd supply part 28 Backup roller 30 Application | coating apparatus 32,52 Bonding roller 34 Curing apparatus 36 Peeling roller 40 Coating film

Claims (10)

  1. 　第１のフィルムを連続搬送しつつ、前記第１のフィルムの表面に活性線硬化型樹脂を含む塗布液を塗布し、塗膜を形成する塗膜形成工程と、
    　第２のフィルムを連続搬送しつつ、前記第２のフィルムを前記塗膜の上にラミネートするラミネート工程と、
    　前記第１のフィルムと前記第２のフィルムとで前記塗膜を挟持して連続搬送しつつ、活性線を照射し、前記塗膜を硬化させて硬化層を形成する硬化工程と、を有し、かつ、
    　前記塗膜形成工程、ラミネート工程および硬化工程を、全て、前記第１のフィルムをバックアップローラに巻き掛けた状態で行うことを特徴とする積層フィルムの製造方法。     While continuously conveying the first film, applying a coating solution containing an actinic radiation curable resin on the surface of the first film, and forming a coating film,
    A laminating step of laminating the second film on the coating film while continuously conveying the second film;
    A curing step of forming a cured layer by irradiating actinic radiation and curing the coating film while sandwiching and continuously conveying the coating film between the first film and the second film. ,And,
    A method for producing a laminated film, wherein the coating film forming step, the laminating step, and the curing step are all performed in a state where the first film is wound around a backup roller.
  2. 　前記ラミネート工程において、前記第２のフィルムを、前記第１のフィルムと離間する貼合ローラに巻き掛けて、前記塗膜の上にラミネートする請求項１に記載の積層フィルムの製造方法。 The method for producing a laminated film according to claim 1, wherein in the laminating step, the second film is wound around a laminating roller separated from the first film and laminated on the coating film.
  3. 　前記貼合ローラとバックアップローラとの距離が、
    　前記第１のフィルムの厚さと前記塗膜の厚さと前記第２のフィルムの厚さとの合計以上である請求項２に記載の積層フィルムの製造方法。     The distance between the bonding roller and the backup roller is
    The method for producing a laminated film according to claim 2, wherein the thickness is equal to or greater than the sum of the thickness of the first film, the thickness of the coating film, and the thickness of the second film.
  4. 　前記貼合ローラとバックアップローラとの距離が、
    　前記第１のフィルムの厚さと前記塗膜の厚さと前記第２のフィルムの厚さとの合計未満である請求項２に記載の積層フィルムの製造方法。     The distance between the bonding roller and the backup roller is
    The manufacturing method of the laminated | multilayer film of Claim 2 which is less than the sum total of the thickness of the said 1st film, the thickness of the said coating film, and the thickness of the said 2nd film.
  5. 　前記バックアップローラと前記貼合ローラとの間隙を調節して、前記貼合ローラに巻き掛けられる第２のフィルムによって前記塗膜の膜厚を調節する請求項４に記載の積層フィルムの製造方法。 The method for producing a laminated film according to claim 4, wherein a film thickness of the coating film is adjusted by a second film wound around the bonding roller by adjusting a gap between the backup roller and the bonding roller.
  6. 　前記第２のフィルムに掛かる張力が１００Ｎ／ｍ以下である請求項１～５のいずれか１項に記載の積層フィルムの製造方法。 The method for producing a laminated film according to any one of claims 1 to 5, wherein a tension applied to the second film is 100 N / m or less.
  7. 　前記硬化工程において、前記塗膜を硬化させる活性線が、波長に対する強度分布の半値幅が１００ｎｍ以下の電磁波である請求項１～６のいずれか１項に記載の積層フィルムの製造方法。 The method for producing a laminated film according to any one of claims 1 to 6, wherein, in the curing step, an active line for curing the coating film is an electromagnetic wave having a half value width of an intensity distribution with respect to a wavelength of 100 nm or less.
  8. 　前記バックアップローラの表面温度を１５～５５℃に調節する請求項１～７のいずれか１項に記載の積層フィルムの製造方法。 The method for producing a laminated film according to any one of claims 1 to 7, wherein a surface temperature of the backup roller is adjusted to 15 to 55 ° C.
  9. 　前記第１のフィルムに掛かる張力をＴ１、前記第１のフィルムの搬送方向のヤング率をＥ１、前記第１のフィルムの厚さをｄ１とし、
    　前記第２のフィルムに掛かる張力をＴ２、前記第２のフィルムの搬送方向のヤング率をＥ２、前記第２のフィルムの厚さをｄ２とした際に、下記式
    ０．０５＜［Ｔ２／（Ｅ２×ｄ２）］／［Ｔ１／（Ｅ１×ｄ１）］＜２０
    を満たす請求項１～８のいずれか１項に記載の積層フィルムの製造方法。     The tension applied to the first film is T1, the Young's modulus in the transport direction of the first film is E1, and the thickness of the first film is d1.
    When the tension applied to the second film is T2, the Young's modulus in the transport direction of the second film is E2, and the thickness of the second film is d2, the following formula 0.05 <[T2 / ( E2 × d2)] / [T1 / (E1 × d1)] <20
    The method for producing a laminated film according to any one of claims 1 to 8, which satisfies:
  10. 　バックアップローラと、
    　第１のフィルムを前記バックアップローラに巻き掛けて連続搬送する搬送手段と、
    　前記バックアップローラに対面して配置される、前記バックアップローラに巻き掛けられた第１のフィルムに、活性線硬化型樹脂を含む塗布液を塗布し、塗膜を形成する塗膜形成手段と、
    　前記塗膜形成手段の前記第１のフィルムの搬送方向下流側に、前記バックアップローラに対面して配置される、第２のフィルムを連続搬送しつつ前記塗膜にラミネートするラミネート手段と、
    　前記ラミネート手段の前記第１のフィルムの搬送方向下流側に、前記バックアップローラに対面して配置される、前記第１のフィルムおよび前記第２のフィルムで前記塗膜を挟持した積層体に活性線を照射する硬化手段と、を有することを特徴とする積層フィルムの製造装置。     A backup roller,
    A conveying means for continuously conveying the first film around the backup roller;
    A coating film forming means for applying a coating liquid containing an active ray curable resin to the first film wound around the backup roller, which is arranged facing the backup roller, and forming a coating film;
    Laminating means for laminating the coating film while continuously transporting the second film, which is arranged facing the backup roller on the downstream side in the transport direction of the first film of the coating film forming means,
    An active line is disposed on the laminate in which the coating film is sandwiched between the first film and the second film, which is disposed on the downstream side of the laminating means in the conveyance direction of the first film so as to face the backup roller. And a curing means for irradiating the laminated film.
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